army tm 9-2320-272-24-4 air force to 36a12- 1 c

ARMY TM 9-2320-272-24-4AIR FORCE TO 36A12- 1 C- 1155-2-4

This publication supersedes TM 9-2320-272-20- 1, October 1985, and changes 1 through 4; TM 9-2320-272-20-2,Oc tobe r 1985 , and changes th rough 3 ; 9 -2320-272-34-1 , 1986 , changes th roughTM 9-2320-272-34-2, June 1986, and changes 1 and 2; and TM 9-2320-358-24&P, October 1992.

TECHNICAL MANUALVOLUME 4 OF 4

UNIT, DIRECT SUPPORT, AND GENERAL SUPPORTMAINTENANCE MANUAL

FORTRUCK, 5-TON, 6X6, M939, M939A1, M939A2

SERIES TRUCKS (DIESEL)

TRUCK, CARGO: 5-TON, 6X6, DROPSIDE,M923 (2320-01-050-2084) (EIC: BRY); M923A1 (2320-01-206-4087) (EIC: BSS); M923A2 (2320-01-230-0307) (EIC: B57);M925 (2320-01-047-8769) (EIC: BRT); M925Al (2320-01-206-4088) (EIC: BST); M925A2 (2320-01-230-0308)(EIC: BS8);

TRUCK, CARGO: 5-TON, 6X6 XLWB,M927 (2320-01-047-8771) (EIC: BRV); M927Al (2320-01-206-4089) (EIC: BSW); M927A2 (2320-01-230-0309) (EIC: BS9);M928 (2320-01-047-8770) (UC: BRU); M928Al (2320-01-206-4090) (EIC: BSX); M928A2 (2320-01-230-0310) (EIC: BTM);

TRUCK, DUMP: 5-TON, 6X6,M929 (2320-01-047-8756) (EIC: BTH); M929Al (2320-01-206-4079) (EIC: BSY); M929A2 (2320-01-230-0305) (EIC: BTN);M930 (2320-01-047-8755) (EIC: BTG); M930Al (2320-01-206-4080) (EIC: BSZ); M930A2 (2320-0l-230-0306) (EIC: BTO);

TRUCK, TRACTOR: 5-TON, 6X6,M931 (2320-01-047-8753) (EIC: BTE); M931A1 (2320-01-206-4077) (EK: BS2); M931A2 (2320-01-230-0302) (EIC: BTP);M932 (2320-01-047-8752) (EIC: BTD); M932Al (2320-01-205-2684) (EIC: 855); M932A2 (2320-01-230-0303) (EIC: BTQ);

TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6,M934 (2320-01-047-8750) (EIC: BTB); M934A1 (2320-01-205-2682) (EIC: BS4); M934A2 (2320-0l-230-0300) (EIC: BTR);

TRUCK, MEDIUM WRECKER: 5-TON, 6X6,M936 (2320-01-047-8754) (EIC: BTF); M936Al (2320-0l-206-4078) (EIC: BS6); M936A2 (2320-01-230-0304) (EIC: BTT).

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

DEPARTMENTS OF THE ARMY AND THE AIR FORCEJUNE 1998

TM 9-2320-272-24-4

WARNING

EXHAUST GASES CAN KILL

1. DO NOT operate vehicle engine in enclosed area.2. DO NOT idle vehicle engine with windows closed.3. DO NOT drive vehicle with inspection plates or cover plates removed.4. BE ALERT at all times for odors.

5. BE ALERT for exhaust poisoning symptoms. They are:Headache

Dizziness

SleepinessLoss of muscular control

6. IF YOU SEE another person with exhaust poisoning symptoms:Remove person from area

Expose to open airKeep person warm

Do not permit person to move

Administer artificial respiration or CPR, if necessary** For artificial respiration, refer to FM 21-11.

7. BE AWARE: The field protective mask for Nuclear, Biological, or Chemical (NBC) protection will notprotect you from carbon monoxide poisoning.THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.

Warning a

TM 9-2320-272-24-4

WARNING SUMMARY

Hearing protection is required for the driver and passenger. Hearing protection is also required forall personnel working in and around this vehicle while the engine is running (AR-40-5 and TB MED501).If required to remain inside vehicle during extreme heat, occupants should follow the water intake,work/rest cycle, and other stress preventive measures (FM 21-10, Field Hygiene and Sanitation).

If NBC exposure is suspected, all air filter media should be handled by personnel wearing protectiveequipment. Consult with your unit NBC officer or NBC NCO for appropriate handling or disposalinstructions.

This vehicle has been designed to operate safely and efficiently within the limits specified in thisTM. Operation beyond these limits is prohibited by IAW AR 70-1 without written approval from thecommander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMCPEO-CM-S,Warren, MI 48397-5000.Never work under dump body unless safety braces are properly positioned. Failure to do this willresult in injury to personnel.During winching operation, never stand between vehicles. Assistant must remain in secondaryvehicle to engage service brake if cable snaps or automatic brake fails while towing vehicle. Failureto do this may result in injury to personnel.Accidental or intentional introduction of liquid contaminants into the environment is in violation ofstate, federal, and military regulations. Refer to Army POL (para. 1-7) for information concerningstorage, use, and disposal of these liquids. Failure to do so may result in injury or death.

Cleaning solvents are flammable and toxic. Do not. use near open flame and always have a fireextinguisher nearby when solvents are used. Use only in well-ventilated places, wear protectiveclothing, and dispose of cleaning rags in approved container. Failure to do this will result in injuryto personnel and/or damage to equipment.

Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed30 psi (207 kPa). Failure to do so may result in injury to personnel.Extreme care should be taken when removing surge tank filler cap if temperature gauge readsabove 175°F (79°C). Steam or hot coolant under pressure will cause injury.Alcohol used in the alcohol evaporator is flammable, poisonous, and explosive. Do not smoke whenremoving alcohol evaporator or adding fluid, and do not drink fluid. Failure to do this will result ininjury or death.Do not perform electrical circuit testing fuel tank with fill cap or sending unit removed. Fuel mayignite, causing injury to personnel.

When performing battery maintenance, ensure batteries are seated and clamped down, all rubberboots are installed, clamps are well down on battery posts, and all battery cables lie flat against thetop of the batteries. Failure to do this may result in injury to personnel and/or damage toequipment.Ensure companion seatbelts are not caught inside battery box. This will cause belts to rot whichmay lead to injury of personnel.On M936/Al/A2 model vehicles, remove spare tire prior to changing tire and install tire in spare tirecarrier after tire change is complete. Operation of crane and/or vehicle engine while vehicle is onjacks may result in injury to personnel or damage to equipment.

Never assemble or disassemble tire and rim assembly while inflated, use inflation to seat lockringon split rim or tire on two-piece rim, or inflate a tire without a tire inflation cage. Injury topersonnel may result.Do not disconnect air lines or hoses, remove safety valves or CTIS components, or perform brakechamber repairs before draining air reservoirs. Small parts under pressure may shoot out with highvelocity, causing injury to personnel.

Warning b

TM 9-2320-272-24-4

WARNING SUMMARY (Contd)

Remove all jewelry when working on electrical circuits. Jewelry coming in contact with electricalcircuits may produce a short circuit, causing extreme heat, explosions, and fling particles of metal.Failure to do so will result in injury or death and damage to equipment.Use eyeshields and follow instructions carefully when performing assembling, disassembling, ormaintenance on this device. Components of this device are under spring tension and may shoot outat a high velocity. Failure to do so will result in injury to personnel.

Do not remove hoses with engine running or start engine with hoses removed. High-pressure fluidsmay cause hoses to whip violently and spray randomly. Failure to do so may result in injury topersonnel.

Keep hands out from between metal surfaces when removing heavy components. Failure to do somay result in injury to personnel.Keep personnel out from under equipment and components of equipment when supported by only alifting device. Sudden loss of lifting power or shift in load may result in injury or death.Do not drain engine, transmission, or radiator fluids, or remove lines containing these fluids, whenhot. Doing so may result in injury to personnel.

Vehicle will become charged with electricity if it contacts or breaks high-voltage wires. Do not leavevehicle while high-voltage lines are in contact with vehicle. Failure to do so may result in injury topersonnel.

Wear hand protection when handling lifting and winching cables, hot exhaust components, andparts with sharp edges. Failure to do so may result in injury to personnel.Do not perform fuel system procedures while smoking or within 50 ft (15.2 m) of sparks or openflame. Diesel fuel is highly flammable and can explode easily, causing injury or death to personneland/or damage to equipment.Ensure drainvalve on aftercooler is open when filling cooling system. Failure to do so may result ininjury to personnel.

Turbocharger intake fins are extremely sharp and turn at very high rpm. Keep hands and looseitems away from intake openings. Failure to do so may result in injury to personnel.Do not place hands between frame and radiator when removing screws from trunnion or liftingradiator. Sudden changes in support may cause the radiator to shift, causing injury to personnel.Air pressure may create airborne debris. Use eye protection or injury to personnel may result.Air system components are subject to high pressure. Always relieve pressure before loosening orremoving air system components.Wear safety goggles when using a hammer.

Ether is extremely flammable. Do not perform ether start system procedures near fire. Injury topersonnel may result.

Warning c/(Warning d blank)

TECHNICAL MANUALNO.9-2320-272-24-4

TECHNICAL ORDER NO. 36A12-1C-1155-2-4

ARMY TM 9-2320-272-24-4AIR FORCE TO 36A12-1C-1155-2-4

HEADQUARTERSDEPARTMENTS OF THE ARMY AND THE AIR FORCE

Washington, D.C., 30 JUNE 1998

TECHNICAL MANUALVOLUME 4 OF 4

UNIT, DIRECT SUPPORT, ANDGENERAL SUPPORT MAINTENANCE MANUAL

FOR

TRUCK, 5-TON, 6X6, M939, M939A1, M939A2 SERIES TRUCKS (DIESEL)TRUCK MODEL EIC NSN WITHOUT WINCH NSN WITH WINCH

Cargo, DropsideCargo, DropsideCargo, DropsideCargo, DropsideCargo, DropsideCargo, DropsideCargoCargoCargoCargoCargoCargoDumpDumpDumpDumpDumpDumpTractorTractorTractorTractorTractorTractorVan, ExpansibleVan, ExpansibleVan, ExpansibleMedium WreckerMedium WreckerMedium Wrecker

M923M923AlM923A2M925M925AlM925A2M927M927AlM927A2M928M928AlM92842M929M929AlM929A2M930M930AlM930A2M931M931AlM931A2M932M932AlM932A2M934M934AlM934A2M936M936AlM936A2

BRYBSSBS7BRTBSTBS8BRVBSWBS9BRUBSXBTMBTHBSYBTNBTGBSZBTOBTEBS2BTPBTDBS5BTQBTBBS4BTRBTFBS6BTT

2320-01-050-20842320-01-206-40872320-01-230-0307

2320-01-047-87712320-01-206-40892320-01-230-0309

2320-01-047-87692320-01-206-40882320-01-230-0308

2320-01-047-87562320-01-206-40792320-01-230-0305

2320-01-047-87702320-01-206-40902320-01-230-0310

2320-01-047-87532320-01-206-40772320-01-230-0302

2320-01-047-87552320-01-206-40802320-01-230-0306

2320-01-047-87502320-01-205-26822320-01-230-0300

2320-01-047-87522320-01-205-26842320-01-230-0303

2320-01-047-87542320-01-206-40782320-01-230-0304

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve theprocedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publicationsand Blank Forms), or DA Form 2028-2 located in back of this manual, directly to: Director, Armament andChemical Acquisition and Logistics Activity, ATTN: AMSTA-AC-NML, Rock Island, IL 61299-7630. A replywill be furnished to you. You may also provide DA Form 2028-2 information via datafax or e-mail:

E-mail: [email protected]: DSN 783-0726 or commercial (309) 782-0726

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

i

TM 9-2320-272-24-4

*This publication supersedes TM 9-2320-272-20-1,24 October 1985, and changes 1 through 4; TM 9-2320-272-20-2,25October 1985, and changes 1 through 3; TM 9-2320-272-34-1, 10 June 1986, and changes 1 through 2; TM 9-2320-272-34-2,10 June 1986, and changes 1 and 2; and TM 9-2320-358-24&P, 21 October 1992.This publication is published in four volumes. TM 9-2320-272-24-1 contains chapters 1,2, and 3 (throughsection IX). TM 9-2320-272-24-2 contains chapters 3 (sections X through XVI) and 4 (sections I through III).TM 9-2320-272-24-3 contains chapter 4 (sections IV through XVI). TM 9-2320-272-24-4 contains chapters 5 and6 and appendices A through H. Volume 1 contains a table of contents for the entire manual. Volumes 1,2, and 3contain an alphabetical index covering tasks found in their respective volume. Volume 4 contains analphabetical index covering all tasks found in the entire manual.

CHAPTER 5

Section I.Section II.

Section III.Section IVSection V

Section VI.Section VII.

CHAPTER 6


Section III.

APPENDIX A

APPENDIX B


Section III.Section IV.

APPENDIX C


APPENDIX D

APPENDIX E

APPENDIX F

APPENDIX G

APPENDIX H

ii

TABLE OF CONTENTS

VOLUME 4 OF 4

GENERAL SUPPORT (GS) MAINTENANCE INSTRUCTIONSPage

. . . . . . . . . . . . . 5-1Engine (M939/Al) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-lEngine (M939A2) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-157TransmissionMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-280Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-398Front and Rear Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-432Special Purpose Bodies Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-463Winch, Hoist, and Power Takeoff (PTO) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-606

SHIPMENT AND LIMITED STORAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . 6-1General Preparation of Vehicle for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Loading and Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2LimitedStorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

MAINTENANCE ALLOCATION CHART (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . B-lIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-lMaintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Tool and Test Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-25Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26

EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST . . . . . . . . . . . . C-1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-lExpendable/Durable Supplies and Materials List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

MANDATORY REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-l

COMMON AND SPECIAL TOOL IDENTIFICATION LIST . . . . . . . . . . . . . . . . E-l

ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . . . . . . F-l

TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-l

SCHEMATIC AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-l

Section I. ENGINE (M939/A1) MAINTENANCE

TM 9-2320-272-24-4

5-1. GENERAL

5-2. ENGINE (M939/A1) MAINTENANCE INDEX

PARA.NO. TITLE PAGE

NO.

5-3.5-4.5-5.5-6.

5-7.5-8.5-9.5-10.5-115-12.

5-13.5-14.

5-15.5-16.5-17.5-18.5-19.5-20.5-21.

5-22.

5-23.

Cylinder Head RepairIntake and Exhaust Valves RefacingValve Seat Inserts MaintenanceFuel Injector Sleeve Maintenance

Cylinder Liners and Block MaintenanceCrankshaft and Main Bearings Maintenance

Camshaft and Gear MaintenancePiston and Connecting Rod MaintenanceEngine Oil Pump RepairMounting Fuel Pump to Holding Fixture

Pressure Gear Pump RemovalGovernor Spring Pack Maintenance

Fuel Pump Housing MaintenanceThrottle Cover and Shaft Maintenance

Governor Weight MaintenanceFuel Pump Setup and CalibrationFuel Injector RepairInjector Leak TestInjector Spray Pattern Test

Injector Test Stand Calibration

Injector Flow Test

5-25-185-225-26

5-345-48

5-585-645-785-925-935-94

5-965-985-1025-1045-122

5-1365-1405-142

5-148

5-1

TM 9-2320-272-24-4

5-3. CYLINDER HEAD REPAIR

THIS TASK COVERS:

a. Disassemblyb. Cleaning

c. Inspectiond. Assembly

INITIAL SETUP:

APPLICABLE MODELS PERSONNEL REQUIREDM939/Al TWO

SPECIAL TOOLSHead holding future (Appendix E, Item 7)Cleaning brush (Appendix E, Item 28)Valve guide arbor (Appendix E, Item 153)Gauge block (Appendix E, Item 52)Crosshead guide puller (Appendix E, Item 106)Crosshead guide spacer (Appendix E, Item 33)

REFERENCES (TM)TM 9-2320-272-24PTM 9-247

EQUIPMENT CONDlTlONCylinder head removed (para. 4-12).

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Outside micrometer (Appendix E, Item 80)Depth micrometer (Appendix E, Item 81)Torque wrench (Appendix D, Item 145)Soft-faced hammer

GENERAL SAFETY INSTRUCTIONSWhen cleaning with compressed air, wear eyeshieldsand ensure source pressure does not exceed 30 psi(207 kPa).

MATERIALS/PARTSSix freeze plugs (Appendix D, Item 133)Sixteen half-keepers (Appendix D, Item 253)Two O-rings (Appendix D, Item 438)Two screw-assembled lockwashers (Appendix D,

Item 578)Gasket (Appendix D, Item 94)Freeze plug (Appendix D, Item 132)Two freeze plugs (Appendix D, Item 134)Lubricating oil (Appendix C, Item 50)Prussian blue (Appendix C, Item 54)Sealing compound (Appendix C, Item 61)Antiseize tape (Appendix C, Item 72)Crocus cloth (Appendix C, Item 20)

a. Disassembly

1. Remove sixteen half-keepers (1) from valve springs (3) and cylinder head (7). Discard sixteen half-keepers (1).

NOTETag springs for installation

2. Remove eight upper spring guides (2), valve springs (3), and lower spring guides (4) from valveguide (5) and cylinder head (7).

3. Tap eight valve (6) stems down lightly to loosen and remove from cylinder head (7). Place onnumbered valve board and hold for inspection.

5-2

TM 9-2320-272-24-4

5-3. CYLINDER HEAD REPAIR (Contd)

5-3

TM 9-2320-272-24-4


4.

5.

Remove two screw-assembled lockwashers (2), plate (3), and two O-rings (4) from cylinder head (11)and fuel crossover connection (5). Discard O-rings (4) and screw-assembled lockwashers (2).

Remove pipe plugs (10) from front and rear face of cylinder head (11). Hold pipe plugs (10) forinstallation.

6. Remove four freeze plugs (8) from exhaust ports (17) on cylinder head (11). Discard freezeplugs (8).

7. Remove two freeze plugs (6) from front and rear face of cylinder head (11). Discard freeze plugs (6).

8. Remove two freeze plugs (1) from cylinder head (11). Discard freeze plugs (1).

9. Remove freeze plug (9) from front of cylinder head (11). Discard freeze plug (9).

5-4

TM 9-2320-272-24-4


5-5

TM 9-2320-272-24-4


b. Cleaning

Clean all cylinder head (1) components (TM 9-247).

c . I n s p e c t i o n

1.

2.

3.4.5.6.

7.

8.

9.

10.

11.

12.

Install four pipe plugs (11) in front and rear face of cylinder head (1).NOTE

Apply sealing compound to outer diameter of freeze plugs beforeinstallation.

Install new freeze plug (10) in front face of cylinder head (1).

Install two new freeze plugs (2) in cylinder head (1).Install two new freeze plugs (7) in front and rear face of cylinder head (1).Install four new freeze plugs (9) in exhaust ports (8) on cylinder head (1).Install two new O-rings (5), plate (4), and two new screw-assembled lockwashers (3) on fuelcrossover connection (6) in cylinder head (1).

CAUTION

Do not use sander to polish cylinder heads. Serious damage togasket sealing surfaces can result.

Clean cylinder head mating surfaces (12) lightly enough to remove all gasket remains and carbondeposits. Inspect in accordance with instructions in para. 5-25.

NOTEInstructions for use of portable magnetic tester are included withthe tester.

Inspect valve seats (13) and injector ports (14) on cylinder head (1) for cracks. If cracks are found,replace cylinder head (1).

NOTEThe following examples of cylinder head defects are provided toassist in determining causes of failures.

Check cylinder head valve seats (13) and injector ports (14) for hot spots and correct probable causes.If this condition exists, probable causes are overheating, loss of coolant, coolant flow stoppage, over-fueling, tight injector holddowns, incorrect injector sleeve installation, defective casting, hotshutdowns, and incorrect insert fittings. If hot spots are found, replace cylinder head (1).

Check cylinder head (1) and water passage holes (15) for pits and scratches. If pits and scratches areless than .003 in. (0.08 mm), remove with crocus cloth. If pits and scratches are more than 0.003 in.(0.08 mm) deep in the area 0.-625-0.156 in. (1.59-3.97 mm) from edge of water passage hole (15),replace cylinder head (1).Check cylinder head surfaces (12) for warped surfaces. If warped surface exceeds 0.002 in. (0.05 mm),replace cylinder head (1).Check cylinder head (1) for required thickness. Cylinder head (1) must measure 4.340 in. (110.24mm) thick. If less than 4.340 in. (110.24 mm) thick, replace cylinder head (1).

5-6

TM 9-2320-272-24-4


5-7

TM 9-2320-272-24-4

5-3. HEAD REPAIR (Contd)

13.

14.

15.

16.

17.

18.

Check valve seat insert (2) and cylinder head (3) for looseness by tapping surface around valve seatinsert (2). Replace valve seat inserts (2) that bounce when tapped (para. 5-4).

Measure width (6) of valve seat insert (2). If width exceeds 0.125 in. (3.18 mm) at any one pointand cannot be narrowed during regrinding, mark valve seat inserts (2) for replacement (para. 5-4).

NOTEThe following examples of valve seat defects are provided to assistin determining causes of failure.

Inspect valve seat insert (2) and cylinder (3) for cracks (1) and correct probable causes. If cracksexist, probable causes are improperly machined insert bore, improper fitting of insert in bore,foreign particle under insert, faulty installation, and overheating.Inspect valve seat insert (2) and cylinder head (3) for bums and correct probable causes. If burned,probable causes are carbon or foreign matter that prevents proper seating of valve. If burned,resurface or replace (para. 5-4).Inspect injector sleeves (4) and cylinder head (3) in accordance with instructions in para. 5-6. Checkinjector sleeves (4) for scratches with bright light. If scratched, mark injector sleeve (4) forreplacement (para. 5-6).Check injector cup seating area (5).a. Lightly coat injector cup (11) with Prussian blue.b. Install injector (9) into sleeve (4) with washer (10), clamp (8), and two screws (7). Tighten

alternately in 4 lb-ft (5.4 N.m) steps to 10-12 lb-ft (14-16 N-m).

c. Remove two screws (7), clamp (8), washer (10), and injector (9).d. Check seat pattern in bottom of sleeve (4) and sleeve seating area (5).e. Blued band (12) on sleeve (4) in sleeve seating area (5) must be 0.060 in. (1.52 mm) minimum

width and be located approximately 0.469 in. (11.91 mm) from bottom of cylinder head (3)surface.

5-8

TM 9-2320-272-24-4


5-9

TM 9-2320-272-24-4


19. Install injector (18) in cylinder head (3) with washer (19), clamp (10), and twoscrews (11). Tighten alternately in 4 lb-ft (5.4 N-m) steps to 10-12 lb-ft (14-16 N-m).

20. Measure protrusion of injector tip (8) with gauge block. Protrusion should be 0.060-0.070 in.(1.52-1.78 mm). If not, mark sleeve (9) for replacement (para. 5-6).

21. Air-test fuel inlet passage (4) and fuel outlet passage (5) for leakage and cracks.

a. Install two O-rings (6), plate (2), and two screw-assembled lockwashers (1).b. Install pipe adapter (151, pipe extension (16), and air pressure gauge (17) into fuel outlet

passage (5).c. Install air hose adapter (121, air pressure control valve (13), and air hose (141 into fuel inlet

passage (4).d. Open air pressure control valve (13) and apply air pressure until air pressure gauge (17) reads

80-100 psi (550-690 pKa), then close valve (13).e. Observe air pressure gauge (17). If pressure drops before fifteen seconds, replace cylinder head (3).

f. If air pressure holds for fifteen seconds, cylinder head (3) is serviceable.NOTE

Replace pipe plugs in fuel passages of cylinder head after removalof test adapters.

22. Remove air pressure gauge (17). pipe extension (16), and pipe adapter (15).23. Remove air hose adapter (12), air pressure control valve (13), and air hose (14) from fuel inlet

passage (4)24. Inspect four crosshead guides (7) in accordance with instructions in para. 2-15.25. Check outside diameter of four crosshead guides (7) using micrometer or dial gauge. If outside

diameter is less than 0.432 in. (10.97 mm), mark guide (7) for replacement.

26. Check four crosshead guides (7) for correct height. If height is not 1.860-1.880 in. (47.24-47.75 mm),mark guide (7) for replacement.

27. Check four crosshead guides (7) for straightness. If guide (7) is not straight, replace guide (7)(subtask d, step 1).

5-10

TM 9-2320-272-24-4


5-11

TM 9-2320-272-24-4


28. Inspect valve crossheads (1) in accordance with instructions in para. 2-15. Discard crossheads (1) ifdefective.a. Check valve crossheads (1) for damaged adjusting screw threads (5) and excessive wear on rocker

lever contact area (2).b. Using micrometer, set small bore gauge at 0.4402 in. (11.181 mm).c. Attempt to insert gauge into bore (4). Discard valve crosshead (1) if bore gauge goes into bore (4).d. Check for out-of-round bore (4) by gauging at several points 90° apart. Discard valve crosshead (1)

if bore (4) is out of round.

e. Check valve stem counterbore depth (3). Discard crosshead (1) if depth (3) is not 0.1200-0.1400 in.(3.048-3.556 mm).

29. Inspect eight valve guides (9) in accordance with instructions in para. 2-15. If defective, mark valveguides (9) for replacement.a. Check eight valve guides (9) for chips, cracks, burrs, or broken out sections. If chipped, cracked,

broken, or burrs are found, mark for replacement.b. Check valve guide (9) for protrusion (7). If protrusion (7) is not 1.270-1.280 in. (32.26-32.51 mm)

above cylinder head surface (8), mark valve guide (9) for replacement.c. Set small bore gauge at 0.4552 in. (11.562 mm) and attempt to insert gauge into guide bore (6). If

gauge goes into bore (6), mark guide (9) for replacement.30. Check valve head (14) and intake and exhaust valves (15) for cracks, warping, pits, burns, or

cupping. Discard valve(s) (15) if cracked or warped, pitted, burned, or cupped.a. Check rim thickness (13) on intake and exhaust valves (15). Discard valve (15) if rim thickness (13)

is less than 0.105 in. (2.67 mm).

b. Check intake and exhaust valve keeper grooves (11) for wear. Use new keeper to check grooves (11).Discard valve(s) (15) if new keepers fit loosely in grooves (11).

c. Check valve stem (12) for cracks, scoring, and galling. If cracked, scored, or galled, discard valve (15).

d. Measure valve stem (10) outside diameter with micrometer. If stem (10) outside diameter is lessthan 0.449 in. (11.41 mm), discard valve (15).

CAUTION

Use care when selecting replacement valve springs. Intermixing ofold and new valve guides in any one cylinder head is permissibleonly if a specific crosshead has two of the same type or equivalentguides and springs installed under it.

31. Inspect valve springs (16) in accordance with instructions in para. 2-15. Discard valve springs (16) ifdefective.a. Check valve springs (16) for distortions, cracked, or collapsed coils. Discard valve spring (16) if

distorted, or if coils are cracked or collapsed.b. Check valve spring (16) free length. No. 1 valve spring is 2.29 in. (58 mm) in length. No 2. valve

spring is 2.69 in. (68 mm) in length.c. Using spring tester, inspect for serviceability by checking load when spring is compressed.

Discard spring No. 1 if spring does not give load of at least 150 lb (667 N) when compressed to1.77 in (45 mm). Discard spring No. 2 if spring does not give load of at least 143 lb (636 N) whencompressed to 1.72 in. (44 mm).

5-12

TM 9-2320-272-24-4


5-13

TM 9-2320-272-24-4


d . Assembly

NOTEUse repaired and inspection-approved cylinder heads only.

1. Replace worn valve guides (3). Drive valve guides (3) from underside of cylinder head (2) withhammer and punch.

2. Using arbor press, mandrel, and valve guide arbor, install new valve guides (3).3. Using crosshead guide puller, remove defective crosshead guides (6) from cylinder head (2).4. Thoroughly clean crosshead guide (9) holes.5. Check crosshead guide (6) height. Assembled height must be 1.860-1.880 in. (47.24-47.75 mm).

To install intake and exhaust valves, position cylinder head onintake port face. Use wooden surface, workbench, or protectivesurface to prevent damage. Bench must be clean.

Be sure to install valves in original locations as numbered instep 3.

Ensure cylinder head is clean

6. Dip valve stem (4) in clean engine oil.7. Install valve stems (4) through valve guides (3) from face side (5) of cylinder head (2). Ensure valve

heads are correctly seated on valve seats (1).

8. Carefully position cylinder head (2) face down on workbench after all valves are installed so valvesprings can be installed.

CAUTION

Two differently-designed valve spring guides have been used inNHC-250 series engines. Part number 128879 spring guidecannot be used with 211999 valve spring. Number 170296spring guide can be used with either valve spring.

Reground valve heads seat deeper in cylinder head, causingvalve stem to protrude farther above valve guide. This allowsvalve spring to extend beyond length limits of 2.250 in. (57.150mm), and causes weak spring action. Use spacers up to 0.0625in. (15.875 mm) to reduce valve spring to proper height.

5-14

TM 9-2320-272-24-4


5-15

TM 9-2320-272-24-4


9.

10.

11.

12.

13.

NOTEA maximum of two 0.03125 in. (0.794 mm) spacers may be usedunder lower spring guide when cylinder head has been resurfacedand valve seat insert has been refaced. Do not use spacers tocompensate for weak springs.

Place eight lower spring guides (18) over valve guides (16) and seat to cylinder head (1).NOTE

Do not mix intake and exhaust springs. Intake springs are taller.Place eight valve springs (15) on lower spring guides (18).Place eight upper spring guides (14) on top of springs (15) and over stem end of valve (8). Compressspring compressor until keeper grooves (12)on valve (8) are exposed.Install new keepers (13) into valve grooves (12) and slowly release spring compressor. Repeat thisstep until all valves (8) are locked by keepers (13).Using vacuum tester, test intake and exhaust valves (8) for proper seating.

a.

b.

C.

d.

e.f.

g.h.i.

j.k.

l.

m.

n.

NOTEValves and valve seats must be dry.Grease can be applied to O-ring on vacuum cup for better seal.

Select correct size vacuum cup (9) for size valves (8) being tested.

Hold vacuum cup (9) over head of valve (8) and seat flat on cylinder head surface (2)surrounding valve (8).Turn tester shutoff valve (6) to open position and hold pushbutton (7) down to operate vacuumpump (4).Operate tester shutoff valve (6) until indicator hand (5) on vacuum gauge (4) stops climbingbetween 18-25 in. (457-635 mm) of mercury. Close tester shutoff valve (7) and releasepushbutton (8).Begin timing as soon as hand (5) reaches 18 in. of mercury on gauge (4).Stop timing as soon as indicator hand (5) reaches 8 in. (20.32 cm) of mercury. If time is lessthan ten seconds, valve (8) seating is not satisfactory

Tap valve stem end with soft-faced hammer and retest by repeating steps a through f.If valve seating is unsatisfactory, proceed to step i.Check for loose connections on tester.Operate vacuum pump (3) with suction cup (9) against a clear glass window.Check indicator hand (5) for movement. If indicator hand (5) moves, there is leakage in thetester.

Tighten connections and retest valves (8).

Repeat steps b through 1.

If test fails, regrind valves before retesting (para. 5-4).

5-16

TM 9-2320-272-24-4


FOLLOW-ON TASK: Install injectors (para. 4-32) Install cylinder head (para. 4-12).

5-17

TM 9-2320-272-24-4

5-4. INTAKE AND EXHAUST VALVES REFACING

THIS TASK COVERS:a. Valve Specifications c. Cleaning after Refacingb. Grinding or Refacing Valves

INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDITIONM939/A1 Cylinder head disassembled (para. 5-3)

TOOLS SPECIAL ENVIRONMENTAL CONDlTlONSGeneral mechanic’s tool kit (Appendix E, Item 1) Well-ventilated work area.Valve refacer

REFERENCES (TM)TM 9-2320-272-24PTM 9-4910-484-10

a. Valve Specifications

NOTEHard-faced exhaust valves are marked by letters “EX” or “HF”in recessed area of valve head. Intake valves are not marked.

Use table 5-l for solid valvesSodium-filled valves are not used in Cummins engines.

5-18

TM 9-2320-272-24-4

5-4. INTAKE AND EXHAUST VALVES REFACING (Contd)

Table 5-1. Valve Specifications.

Ref. Intake and New NewExhaust Valves Minimum Maximum

1 Stem 0.4500 in. 0.4510 in.

(11.4300 mm) (11.4554 mm)

2 Seat angle 30° 30°

3 Refacing depth 0.0625 in.(1.59 mm)

4 Valve head thickness 0.105 in.(2.67 mm)

Wornlimits

0.4990 in.(11.4046 mm)

0.0625 in

(1.59 mm)0.105 in.(2.67 mm)

5-19

TM 9-2320-272-24-4


1.2.

3.4.

5.6.7.

8.9.

10.

11.

12.

NOTEMark on ground face of valve. Mark is used to determine heador stem warpage.

For operating instructions of valve refacer, refer toTM 9-4910-484-10.

Install valve (3) stem in chuck (2).Turn switch (5) of valve refacer to ON to start valve grinder electric motor.

NOTEAn out-of-round condition of valve will be marked by a smallbright spot on valve seating surface of valve head.

Turn grinder wheel handle (6) and very lightly touch valve (3) face with grinder wheel (4).Move grinder wheel (4) away from valve head and switch valve grinder electric motor to OFF withvalve refacer switch (5).Indicate location of small bright spot on ground face of valve (3).Rechuck valve (3) 180° from first position and mark new position on valve (3).

Turn valve refacer switch (5) to ON to start valve refacer electric motor.

Turn grinder wheel (4) handle (6) and very lightly touch valve (3) face with grinder wheel (4).Move grinder wheel (4) away from valve (3) head and switch grinder electric motor to OFF withswitch (5).If bright spot is in the same position after both chucking operations, the valve (3) is warped. If valve (3)is warped, replace valve (3).If bright spots occur in different positions, the chuck (2) is out of alignment or the valve (3) is beingincorrectly chucked. Run-out should not exceed 0.0001 in. (0.0254 mm).

NOTEUse valve refacer handle for left and right motion of valve.

Wet grind valves (3) to an exact 30° angle from horizontal and check valve (3) head rim thicknesswith wheel handle (7) controlling depth of grind (table 5-l).

NOTEKeep valves in order in a numbered valve stick or board.

NOTEDo not use cloth to wipe valves clean.

1. Clean refaced valves (3). For general cleaning instructions, refer to para. 2-14.

5-20

TM 9-2320-272-24-4


FOLLOW-ON TASK: Assemble cylinder heads (para. 5-3).5-21

TM 9-2320-272-24-4

5-5. VALVE SEAT INSERTS MAINTENANCE

THIS TASK COVERS:

a. Removalb. Gaugingc. Counterboring

d. Cleaninge. Installation

INITIAL SETUP:

APPLIABLE MODELSM939/Al

MATERIALS/PARTSValve seat inserts (Appendix D, Item 708)

SPECIAL TOOLSValve seat insert tool (Appendix E, Item 158)Cutter seat (Appendix E Item 34)

Drycleaning solvent (Appendix C, Item 71)

REFERENCES (TM)TM 9-2320-272-24P

Valve guide arbor (mandrel set) (Appendix E,Item 154) EQUIPMENT CONDlTlON

Tool driver (Appendix E, Item 140) Cylinder head disassembled (para. 5-3).Valve seat insert staking tool (Appendix E,

Item 157) GENERAL SAFETY INSTRUCTIONSValve seat insert extractor (Appendix E, When cleaning with compressed air, wear

Item 156) eyeshields and ensure source pressure does not

TOOLSexceed 30 psi (207 kPa).Keep fire extinguisher nearby when using

General mechanic’s tool kit (Appendix E, Item 1) drycleaning solvent.Inside micrometer (Appendix E, Item 82) Drycleaning solvent is flammable and toxic. DoOutside micrometer (Appendix E, Item 80) not use near an open flame.Vernier calipers (Appendix E, Item 159)Depth gauge (Appendix E, Item 81)BrushElectric drill

1. Pull valve seat insert (3) from bore (2) on cylinder head (1) with valve seat insert extractor tool.

CAUTION

Each replacement valve seat insert outside diameter andthickness must be measured and compared to relating valve seatinsert counterbore in the cylinder head before counterboring.These measurements will prevent over-boring and damage to thecylinder head.

1. Measure outside diameter of valve seat insert (3) using micrometer. Record reading and comparewith specifications in table 5-2.

2. Measure thickness of valve seat insert (3). Record reading and compare with specifications in table5-2.

3. Measure valve seat counterbore (4) depth (5) with depth micrometer. Record reading and compare tospecifications in table 5-2.

4. Measure valve seat insert counterbore (4) inside diameter with inside micrometer. Record readingand compare to specifications in table 5-2.

5-22

TM 9-2320-272-24-4

5-5. VALVE SEAT INSERTS MAINTENANCE (Contd)

Table 5-2. Valve Seat Specifications.

CYLINDER HEADVALVE SEAT

COUNTERBORE DEPTH

Standard

CYLINDER HEADINSERT COUNTERBORE INSERT

OUTSIDE DIAMETER INSIDE DIAMETER THICKNESS

2.0025 - 2.0035 in. 1.9995 - 2.0005 in. 0.278 - 0.282 in.(50.864 - 50.889 mm) (50.787 - 50.813 mm) (7.0612 - 7.1629 mm)

5-23

TM 9-2320-272-24-4


c. Counterboring

1. Clamp base (2) of counterbore cutter (7) to cylinder head (3) near valve insert seat bore (4). Ensurecounterbore cutter (7) is securely clamped before starting electric drill motor (1).

NOTEAllow cutter to turn several revolutions at exact moment theproper depth in cylinder head is reached to ensure a perfectly flatbottom of bore for valve seats to seat.

2. Center counterbore cutter (7) in valve seat insert bore (4) and valve guide mandrel (6).3. Cut counterbore (5) 0.006-0.010 in. (0.1524-0.2540 mm) deeper than valve seat insert thickness to

allow staking (peening) of cylinder head (3) to secure valve seat insert.

Eyeshields must be worn when cleaning with compressed air.Compressed air source will not exceed 30 psi (207 kPa). Failure todo so may result in injury to personnel.

1. Blow cylinder head (3) out with compressed air.

WARNING

Drycleaning solvent is flammable and toxic. Do not use near openflame and always have a fire extinguisher nearby when solventsare used. Use only in well-ventilated places, wear protectiveclothing, and dispose of cleaning rags in approved container.Failure to do this may result in injury or death to personnel and/ordamage to equipment.

2. Clean opening and ports of cylinder head (3) with brush and drycleaning solvent.

3. Dry cylinder head (3) with compressed air.

e. Installation

CAUTION

Valve seat inserts may be installed one time only. If valve seatinsert is not properly installed the first time, a new valve seatinsert must be installed.

NOTEKeep valve seat inserts in cold storage until ready to install incylinder head. Install valve seat insert very quickly so roomtemperature does not have a chance to expand insert and make itdifficult to install.

1. Drive valve seat insert (9) into valve seat insert bore (4) with valve seat insert tool until fully seated.

2. Stake (peen) valve seat insert (10) into cylinder head (3) with valve seat insert tool and valve seatinsert staking tool.

5-24

TM 9-2320-272-24-4


FOLLOW-ON TASK: Grind valve seats (para. 5-2).

5-25

TM 9-2320-272-24-4

5-6. FUEL INJECTOR SLEEVE MAINTENANCE

THIS TASK COVERS:

a. Removalb. Bead Cuttingc. Installation

d. Fitting and Forminge. Check and Test

INITIAL SETUP:

APPLICABLE MODELSM939lAl

SPECIAL TOOLSBead cutting tool (Appendix E, Item 9)Injector sleeve expander tool (Appendix E,

Item 73)Injector sleeve cutter (Appendix E, Item 72)Injector protrusion gauge (Appendix E, Item 53)Injector sleeve holding tool (Appendix E,

Item 74)Injector sleeve installation mandrel (Appendix

E, Item 75)Injection sleeve extractor (Appendix E,

Item 67)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 146)Dial indicator (Appendix E, Item 36)Drill press

MATERIALS/PARTSInjector sleeve (Appendix D, Item 257)Injector sleeve O-ring (Appendix D, Item 478)Cutting oil (Appendix C, Item 26)Lubricating oil (Appendix C, Item 50)Prussian blue (Appendix C, Item 54)


EQUIPMENT CONDITIONCylinder head disassembled (para. 5-3).

1.2.3.4.

5.6.

7.8.

Place cylinder head (5) on workbench with exhaust manifold side down.Insert tapered end of lower puller collar (7) into injector sleeve (6).Insert upper puller collar (9) on top of collar (7) with threaded end out.Position support bridge (10) over threaded end of collar (9) with one hand holding supportbridge (10) legs against cylinder head (5) and install washer (11) and nut (12). Tighten nut (12)finger tight.

While holding support bridge (10) insert threaded rod (4) through holes in collars (7) and (9).Install hex nut (1) and extractor tip (3) on threaded rod (4) and tighten. Ensure extractor tip (3) isseated firmly against injector sleeve (6) bottom.Tighten nut (1) to remove injector sleeve (6). Discard injector sleeve (6).Remove O-ring (8) from injector sleeve bore (2). Discard O-ring (8).

5-26

TM 9-2320-272-24-4

5-6. FUEL INJECTOR SLEEVE MAINTENANCE (Contd)

5-27

TM 9-2320-272-24-4


1. Insert cylinder head (5) cutter (3) and cutter pilot (2) into injector sleeve bore (6).2. Position holder (1) to cutter (3).

3. Set cylinder head (5) on table of drill press.CAUTION

Tool chatter may occur if drill speed is higher than 75 rpm,causing damage to cylinder head.

Do not cut more than 0.010 in. (0.254 mm) deep into cylinderhead.Cutter must be sharp to prevent bead damage.

NOTEPress may be turned by hand for light cuts or to preventaccidental removal of too much material.

4. Set drill press speed no higher than 75 rpm.5. Lift holder (1), pilot (2), and cutter (3) and apply cutting oil to lubricate cutter (3).6. Turn drill press motor on and take a very light cut. When the proper cut depth has been reached,

allow cutter (3) to dwell ten seconds to ensure a good seat and to clean the groove.7. Remove holder (1), pilot (2), and cutter (3) from injector sleeve bore (6).

8. Apply Prussian blue to coat seat end of new injector sleeve (7) and insert new injector sleeve (7) ininjector sleeve bore (6) until fully seated.

9. Remove new injector sleeve (7) from injector sleeve bore (6). Ensure blueing shows a complete 360°band on both the injector sleeve (7) and seat (4).

Ensure sleeve seat at bottom of injector bore is free from oil,carbon, or other foreign materials.

1. Apply lubricating oil to coat new O-ring (10).

2. Install new O-ring (10) into groove (11) of injector sleeve bore (6).NOTE

Ensure mandrel is not struck with a hammer during thisoperation.

3. Use injector sleeve mandrel to push the new injector sleeve (7) into injector sleeve bore (6) until itbottoms.

4. Remove mandrel from injector sleeve bore (6).

5. Install injector sleeve holding tool (8) in cylinder head (5). Tighten nut (9) 35-40 lb-ft(48-54 N•m)

6. Insert injector sleeve mandrel into injector sleeve bore (6) and drive injector sleeve (7) in with soft-faced hammer until seated.

7. Retighten nut (9) 35-40 lb-ft (48-54 N•m).

5-28

TM 9-2320-272-24-4


5-29

TM 9-2320-272-24-4


CAUTION

Do not roll lower area of injector sleeve which will causedistortion of total sleeve.

Over-rolling of injector sleeve will cause deformation of sleeveinto O-ring groove.

1. Position injector sleeve expander tool into injector sleeve (2) in cylinder head (1).2. Turn thrust nut (4) to adjust depth of expander tool so that roller (3) extends 0.5 in. (12.7 mm) into

sleeve (2).3. Lock thrust nut (4) in place using an Allen wrench.

4. Push expander tool down, turn, and adjust until 75 lb-in. (8.5 N-m) maximum is reached.NOTE

Form cutter per specifications in table 5-3.Table 5-3. Cutter Specifications.

Item

5

6

7

8

910

11

121314

1516

1718

19

20

21

22

In.

0.0800.090

0.00150.00250.00770.00971.06151.0635

15° angle relief

15° angle relief

30° 9’ angle relief

0.3750.3120.125

0.3750.010

0.09370.384

0.3860.2260.236

0.3425

1.250

0.375

(MM)(2.0320)(2.2860)

(0.0381)(0.0635)(0.1955)(0.2463)

(26.9621)(27.0129)

(9.5250)(7.9375)(3.1750)

(9.5250)(0.2540)

(2.3812)(9.7536)

(9.8044)(5.7404)(5.9944)(8.6995)

(31.7500)

(9.5250)

5-30

TM 9-2320-272-24-4

5-6. FUEL INJECTOR SLEEVE MAINTENANCE (Contd) I

5-31

TM 9-2320-272-24-4


5. Size, grind, and inspect injector sleeve seat cutter (5) and ensure it is ground to exact contourslisted in table 5-3.

NOTEUse a solid stream of clean cutting oil to allow injector sleeveseat cutter to cut freely without grabbing.

Proper seating and protrusion of injector sleeve seat cutter arechecked in task e.

6. Install injector sleeve seat cutter (5) on head (6) and use in drill press with pilot (4) to cut injectorsleeve (2) just enough to provide for proper seating of injector and to maintain correct injector tipprotrusion.

e. Check and Test

1.

2.3.4.

5.

6.

NOTESteps 1 through 4 check injector cup seating pattern in injector.

Apply light coat of Prussian blue to injector cup (11) and install injector assembly (9) into cylinderhead (1) with washer (10), clamp (8), and two screws (7). Tighten screws (7) alternately in4lb-ft (5 N•m) steps to l0-12 lb-ft (14-16 N•m).Remove two screws (7), clamp (8), washer (l0), and injector assembly (9) from cylinder head (1).Check seat pattern in bottom of injector sleeve (2) cup seating area.If blued band (3) on injector sleeve (2) seating area is not at least 0.060 in. (1.52 mm) wide andlocated approximately 0.469 in. (11.91 mm) from bottom of cylinder head (1) surface, regrindinjector sleeve (2) seating area as described in steps 5 and 6 of task f.

Install injector assembly (9) in injector sleeve (2) in injector head (1) with clamp (8), washer (10),and two screws (7). Tighten screws (7) alternately in 4 lb-ft (5 N•m) steps to 10-12 lb-ft. (14-16 N•m).

Check protrusion of injector tip (13) using dial indicator (12).a. If injector tip (13) protrusion exceeds 0.070 in. (1.78 mm), install new injector sleeve (2).b. If injector tip (13) protrusion is less than 0.060 in. (1.52 mm), regrind injector sleeve (2).

5-32

TM 9-2320-272-24-4


FOLLOW-ON TASK: Assemble cylinder head (para. 5-3).

5-33

TM 9-2320-272-24-4

5-7. CYLINDER LINERS AND BLOCK MAINTENANCE

THIS TASK COVERS:a. Removal c. Cleaning and Inspectionb. Disassembly d. Cylinder Liners Installation

INITIAL SETUP:

APPLICABLE MODELSM939/A1

SPECIAL TOOLS


EQUIPMENT CONDITIONCrankshaft and main bearings removed (para. 5-8).Liner clamp set (Appendix E, Item 78)

Liner driver (Appendix E, Item 79)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Cylinder liner puller (Appendix E, Item 107)Outside micrometer (Appendix E, Item 80)Vernier calipers (Appendix E, Item 159)Depth gauge (Appendix E, Item 81)Gauge block (Appendix E, Item 52)Dial indicator (Appendix E, Item 36)Telescoping gauge set (Appendix E, Item 136)Torque wrench (Appendix E, Item 144)Feeler gaugeHold-down tool

MATERIAL PARTS

GENERAL SAFETY INSTRUCTIONSKeep fire extinguisher nearby when usingdrycleaning solvent.Drycleaning solvent is flammable and toxic. Donot use near an open flame.When cleaning with compressed air, weareyeshields and ensure source pressure does notexceed 30 psi (207 kPa).

SPECIAL ENVIRONMENTAL CONDITIONSWork area clean and free from blowing dirt anddust.

Two lockwashers (Appendix, Item 349)Suction flange gasket (Appendix D, Item 680)Two O-rings (Appendix D, Item 460)Crevice seal (Appendix D, Item 88)Drycleaning solvent (Appendix C, Item 71)Antiseize tape (Appendix C, Item 72)Lint-free cloth (Appendix C, Item 21)Lubricating oil OE/HDO (Appendix C, Item 50)Detergent (Appendix C, Item 27)

NOTETag all cylinder liners for installation.

Remove six cylinder liners (1) from cylinder liner bores (2) with cylinder liner puller.

5-34

TM 9-2320-272-24-4

5-7. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd)

5-35

TM 9-2320-272-24-4


1.

2.

3.

4.

5.6.7.8.

NOTEAll six cylinder liners are repaired the same way. This procedurecovers only one cylinder liner.

Remove upper and lower O-rings (4) and (5) and crevice seal (3) from cylinder liner (1). Discard O-rings (4) and (5) and crevice seal (3).Remove shim pack (2) from cylinder liner (1) and measure thickness with micrometer. Recordreadings so same shim pack (2) thickness can be installed.Tape shim pack (2) together and tag with corresponding cylinder liner (1) number. Hold shimpack (2) for reassembly.Place cylinder liner (1) on numbered rack and hold for cleaning and inspection.

NOTENote location of plug removal for installation.

Remove four water passageway pipe plugs (6) from engine block (7).Remove eight oil passageway pipe plugs (9) from engine block (7).Remove two water passageway cup plugs (8) from engine block (7).Remove two screws (11), lockwashers (12), suction flange plate (10), and gasket (13) from engineblock (7). Discard lockwashers (12) and gasket (13) and clean gasket remains from mating surfaces.

5-36

TM 9-2320-272-24-4


5-37

TM 9-2320-272-24-4


WARNING


1.2.

Clean engine block (1). Refer to para. 2-14 for general cleaning instructions.Run rods (3) with brushes through all oil passages (2) in engine block (1).

3.4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

WARNING


Blow oil passages (2) of engine block (1) clean with compressed air.Clean water pump air bleed hole (4) in cylinder bore (5) with compressed air.Blow all dirt and cleaning solvent from all engine block (1) screw holes (7).Remove scale from liner counterbore ledge (6).

Clean carbon from lower liner bore (8) of engine block (1).NOTE

Ensure engine block is on flat surface or workbench for inspection.Refer to para. 2-15 for general engine block (1) inspection instructions.Check engine block (1) for worn surfaces, pitting, corrosion, nicks, gouges, burrs, eroded waterholes,damaged threads, distortion, and cracked areas.Inspect counterbore ledge (6) of cylinder liner counterbore (9) at points (A) and (B) to ensurecounterbore ledge (6) is 90° to liner bore.Check counterbore diameter (A) and depth (B) to insure proper seating of cylinder liner and todetermine if machining of counterbore ledge (6) depth is necessary.

NOTEIf counterbore depth varies more than 0.001 in. (0.03 mm) atseveral areas measured or counterbore slants downward towardcenter of cylinder liner bore, counterbore ledge will need to berefinished.

Steps 12 and 13 check engine block for possible counter-boredistortion.

Position telescoping gauge in counterbore (9) and set dial to zero.

Move bore gauge around circumference of counterbore (9) and take readings at three intervalsof 120°. The difference in the readings will indicate amount of distortion. If specifications intable 5-4 are exceeded, replace engine block (1).

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Table 5-4. Cylinder Liner Counterbore.

INSlDE DIAMETER DEPTH

New minimum . . . . . . . . . . . . . . . . . . . . . . . . 6.5615 in. 0.350 in.(166.662 mm) (8.89 mm)

New maximum . . . . . . . . . . . . . . . . . . . . . . . . 6.5635 in. 0.352 in.(166.713 mm) (8.94 mm)

Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.412 in.(10.56 mm)

14. Ensure cylinder liners (2) protrude 0.003-0.006 in. (0.08-0.15 mm) above the engine block (1) whenthey are properly installed.

NOTEShims are used to compensate for counterbore depth wear.Steps 15 through 17 check cylinder liner for proper protrusionwithout installing a cylinder liner.

15. Measure cylinder liner (2) outside flange (4) with micrometer. Do not include bead (3) when takingmeasurements.

16. Measure counterbore ledge (5) depth with gauge block. Ensure counterbore ledge (5) is smooth andnot “cupped” more than 0.0014 in. (.036 mm). Depth must not vary more than 0.001 in. (0.254 mm).

17. Subtract counterbore depth from cylinder liner (2) outside flange (4) depth to determine amount ofshims or depth of counterbore cut to be made to obtain 0.0036-0.006 in. (0.08-0.15 mm) linerprotrusion.

18. Install cylinder liner (2) and clamps in engine block (1) without O-rings or crevice seal. Ensureclamps are installed so there is equal pressure on liner. Tighten clamps 50 lb-ft (68 N•m).

19. Use feeler gauge to check clearance between lower liner (2) and engine block (1). If clearance is notwithin limits specified in table 5-5, check lower O-ring groove inside diameter in engine block (1).

20. Remove cylinder liner (2) from engine block (1).

21. Use telescoping gauge to check lower liner bore (6) in engine block (1). Bore (6) should be withinlimits set in table 5-5.

Table 5-5. Lower Liner Bore Inside Diameter and Block Clearance.

MINIMUM

Lower liner bore inside diameter . . . . . . . . . . . . . . . 6.124 in.(155.55 mm)

Lower liner to block clearance . . . . . . . . . . . . . . . . . 0.002 in.(0.05 mm)

MAXIMUM

6.126 in.(155.60 mm)

0.006 in.(0.15 mm)

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22. Install main bearing caps (2) in engine block (1) without crank or bearing shells.23. Measure main bearing bore diameter (3) horizontally, vertically, and diagonally with telescoping

gauge (4). Ensure bore diameter does not exceed 4.75 in. (120-663 mm).NOTE

Pipe plugs, cup plugs, and suction flange plate are installed at thistime to keep passages clean. Wrap pipe plug threads with sealingtape to prevent leakage.

24. Install two cup plugs (9) in engine block (1).25. Install four pipe plugs (8) in block (1) and tighten according to table 5-6.26. Install eight pipe plugs (10) in block (1) and tighten according to table 5-6.27. Install new gasket (14) and suction flange plate (13) on engine block (1) with two new

lockwashers (12) and screws (11). Tighten screws (11) 10-15 lb-ft (14-20 N•m).

Table 5-6. Engine Block Pipe Plug Torque.

PIPE PLUG SIZE

1/8 in. 15 (20)1/4 in. 30 (41)3/8 in. 35 (47)1/2 in. 45 (61)3/4 in. 60 (81)

1-1/4 in. 75 (102)1-1/2 in. 90 (122)

MINIMUMLB-FT (NM

MAXIMUMLB-FT (N•M)

20 (27)35 (47)45 (61)

55 (75)70 (95)

85 (115)

100 (136)

NOTE

Most attempts to hone or deglaze cylinder liners provide worseresults than leaving them “as is”. Experience and laboratoryresults indicate that liners do not need to be honed, rotated, ordeglazed to provide proper setting.

It is recommended that cylinder liners be inspected beforecleaning so defects can be clearly noted.

Inspect cylinder liners closely for any of the metal conditionsillustrated. If one liner has failed, then other liners in the sameengine are likely to have early signs of the same type of failure.

28. Check cylinder liner (5) for scoring or vertical grooving (6) on the inside diameter indicating heavymetal-to-metal contact of piston to cylinder liner (5). If scoring or vertical grooving (6) is present, tagcylinder liner for replacement.

29. Check cylinder liner (5) for cracks (7) indicated by magnetic detection. If cracks (7) are present, tagcylinder liner (5) for replacement.

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30.

31.

32.

33.

34.

35.

36.

37.38.

39.40.

41.

Check cylinder liner (2) for a series of pit erosions (3) on the thrust or antithrust side of the cylinderliner (2) outside diameter. If pit erosions (3) are present, tag cylinder liner (2) for replacement.

Check cylinder liner (2) for visible cracks. As a rule, cylinder liners are highly resistant to verticalcracks or breakage. If cracks are present, tag cylinder liner (2) for replacement.

Check cylinder liner (2) for eroded surface (4). Moving coolant contacting the cylinder liner (2)outside diameter erodes the surface away and attacks the crevice seal. If surface is eroded (4),tag cylinder liner (2) for replacement.Check cylinder liner (2) for fretting of surfaces (6), and/or machined area. Top of cylinder linerbead has worn away on illustrated cylinder liner (2). If surfaces (6) have fretted, tag cylinderliner (2) for replacement.

NOTEDo not use wire brush on cylinder liners.

Steam, clean, or wash cylinder liner (2) in hot water and detergent. Scrub with bristle brush.

Remove rust, scale, and corrosion from cylinder liner (2). If cylinder liner (2) is excessively rusted,scaled, or corroded, replace.

WARNING


Blow cylinder liner (2) dry with compressed air.Apply generous coat of lubricating oil to cylinder liner (2) and let stand for five to ten minutes.

Wipe oil from cylinder liner bore (1) with heavy paper towel. Gray and black residue will appear ontowels.Repeat steps 37 and 38 until black or gray residue no longer appears on towel.Apply lubricating oil lightly to cylinder liners (2) and wrap cylinder liners (2). Store in clean, drylocation until installation.

NOTECylinder liners must be checked at 60°-70°F (16°-21°C). Newcylinder liners with lubrite finish may be 0.0002-0.0006 in.(0.005-0.015 mm) smaller than indicated due to lubrite coating.

Check liner bore (1) with telescoping gauge. If measurement exceeds 5.5050 in. (139.830 mm), tagcylinder liner (2) for replacement.

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d. Cylinder Liners Installation

1. Clean cylinder liner flange (2), crevice seal groove (12), and O-ring grooves (3) and (11) with lint-freecloth.

2. Install new crevice seal (10) in crevice seal groove (12). Ensure crevice seal (10) is straight and nottwisted.

3. Install new black O-ring (9) in top O-ring groove (11) using molding mark as a guide. Ensure newblack O-ring (9) is straight and not twisted.

4. Install new red O-ring (9) in bottom O-ring groove (3). Ensure new red O-ring (9) is straight and nottwisted.

5. Clean cylinder bore (7), counterbore (4), and lower bore (5) and apply lubricating oil.6. Apply light coat of clean engine oil to crevice seal (11) and O-rings (8) and (9) and position cylinder

liner (1) in engine block (6) by hand. Take care not to dislodge O-rings (8) and (9) and crevice seal (10).Press cylinder liner (1) in place using hand pressure.

NOTEInstall cylinder liner without shims until liner protrusion ischecked in step 8. It may be necessary to remove liners and addshims.

7. Drive cylinder liner (1) in with liner driver and liner clamp until cylinder liner flange (2) is seated.Hold down with hold-down tool.

8. Position dial indicator and gauge block on cylinder liner (1) and measure cylinder liner (1) protrusion.If protrusion is not 0.003-0.006 in. (0.08-0.15 mm), add or remove shims and repeat task d.

NOTEWhen performing step 9, if liner is more than 0.002 in. (0.05 mm)out-of-round in lower bore O-ring area, remove liner and check forcause of distortion. It is permissible to have 0.003 in. (0.08 mm)out-of-round at the top 1 in. (25.4 mm) of liner bore.

9. Position telescoping gauge in cylinder liner (1) and measure at several points within rangetravel for out-of-round condition. If out-of-round, remove cylinder liner (1) and reinstall.

of piston

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FOLLOW-ON TASK: Install crankshaft and main bearings (para. 5-8).

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5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE

THIS TASK COVERS:

a. Removal c. Installationb. Cleaning and Inspection d. End Play Clearance

INITIAL SETUP:


TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Main bearing cap puller (Appendix E, Item 108)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)Torque wrench (Appendix E, Item 144)Dial indicator (Appendix E, Item 36)HoistRubber-protected hooks

MATERIALS/PARTSCrankshaft main bearing set

(Appendix D, Item 87)Thrust ring set (Appendix D, Item 682)Fourteen lockplates (Appendix D, Item 341)Woodruff Key (Appendix D, Item 738)Fourteen dowel rings (Appendix D, Item 100)Lint-free cloth (Appendix C, Item 21)GAA grease (Appendix C, Item 28)Lubricating oil (Appendix C, Item 50)Drycleaning solvent (Appendix C, Item 71)


EQUIPMENT CONDITIONConnecting rod and pistons removed (para. 5-10).

GENERAL SAFETY INSTRUCTIONSl Keep fire extinguisher nearby when using

drycleaning solvent.l Drycleaning solvent is flammable and toxic. Do

not use near an open flame.l When cleaning with compressed air, wear

eyeshields and ensure source pressure does notexceed 30 psi (207 kPa).

a. Removal

1. Turn engine block (1) upside down.2. Bend down lockplate tab (8) and remove two screws (7) from seven main bearing caps (9). Discard

lockplates (8).NOTE

Tag all bearing caps and bearing shells for installation.

3. Remove main bearing caps (9) from engine block (1) with main bearing cap puller.4. Remove lower half bearing shell (10) from main bearing caps (9). Discard lower half bearing shell (10).5. Remove lower half of thrust ring (4) from crankshaft near journal (5). Discard thrust ring (4).6. Carefully remove crankshaft (6) from engine block (1) using hoist and rubber-protected hooks (11).

Place crankshaft (6) on clean, flat surface.7. Remove upper half bearing shells (2) from engine block (6). Discard upper half bearing shells (2).

8. Remove fourteen dowel rings (3) from engine block (1). Discard dowel rings (3).9. Remove upper half of thrust ring (4) from engine block (1). Discard thrust ring (4).

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5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE (Contd)

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b. Cleaning and Inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

WARNING

Drycleaning solvent is flammable and toxic. Do not use near openflame and always have a tire extinguisher nearby when solventsare used. Use only in well-ventilated places, wear protectiveclothing, and dispose of cleaning rags in approved container.Failure to do this may result in injury or death to personnel and/ordamage to equipment.

Clean crankshaft (2) and crankshaft gear (6) with drycleaning solvent. For cleaning instructions,refer to para. 2-14.Inspect crankshaft gear (6) for breaks, cracks, or chips. If broken, cracked, or chipped, replacecrankshaft (2) assembly.Wipe rear No. 7 main bearing journal thrust flange (1) clean and check stamping (4) onshaft web (5). Stamped numbers show standard or oversize thrust rings both front and rear.Inspect rear No. 7 main bearing journal thrust flange (1) for scratches or scoring. If scratched orscored, regrind and stamp shaft web (5) accordingly.

CAUTION

If any one bearing shell half is damaged, all bearing shells mustbe discarded. Not doing so will vary oil clearance limits wheninstalled in engine and cause lubrication problems.

Wipe lower and upper half main bearing shell (7) clean and inspect for pits, chips, and scratches.If pitted, chipped, or scratched, replace bearing set.Measure thickness of lower and upper half main bearing shell (7). If thickness is less than 0.1215in. (3.086 mm), replace bearing set.Wipe crankshaft main bearing journals (3) clean with lint-free cloth and inspect for out-of-roundcondition. Measure out-of-round condition with micrometer. If out-of-round more than 0.002 in.(0.05 mm), replace crankshaft (2).

Measure outer diameter of crankshaft main bearing journals (3) with micrometer. If outer diameteris less than 4.4975 in. (114.237 mm), repair and stamp on front counterweight (8) accordingly.Wipe lower and upper half rod bearing shell (7) clean and inspect for pits, chips, and scratches. Ifpitted, chipped, or scratched, replace bearing set.Measure lower and upper half rod bearing shell (7) thickness with micrometer. If thickness is lessthan 0.071 in. (1.80 mm), replace bearing set.Wipe crankshaft rod journals (9) clean with lint-free cloth and measure outer diameter withmicrometer. If outer diameter is less than 3.122 in. (79.30 mm), repair and stamp on frontcounterweight (8) accordingly.Measure outer diameter of rear counterweight seal flange (10) with micrometer. If outer diameter isunder 5.997 in. (152.94 mm), replace crankshaft (2).

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c. Installation

1.

2.

3.

4.5.

6.

7.

8.

WARNING


Ensure main bearing bores (3) of engine block (1) are facing up.

Clean all engine block screw holes (2) with compressed air.

Wipe all engine block bearing bores (3) clean with lint-free cloth.CAUTION

Touching bearing shell wear surface after shells have been cleanedwill cause shell corrosion, resulting in engine damage.

NOTECount new bearing upper shells from front of engine block.

Wipe new bearing upper shells (4) Nos. 1, 2, 3, 4, 5, and 6 (4) clean with lint-free cloth.Position new bearing upper shells (4) Nos. 1, 2, 3, 4, 5, and 6 (4) in bearing bores (3) with oil holes(5) aligned and press in place. Apply coat of lubricating oil. Bearing shell (4) will project slightlyabove bore (3).

NOTEWide portion of upper bearing shell is measured from oil groove toedge.

Install new bearing upper shell No. 7 (7) in bore (10) with wide portion (8) toward flywheel end ofblock (1).

Align new bearing upper shell No. 7 oil holes (9) and press in place. Apply coat of lubricating oil.Bearing shell (7) will project slightly above bore (10).Install fourteen new dowel rings (6) in engine block (1).

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5-53

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9.10.

11.

12.

13.14.

15.

16.

17.

Wipe clear surfaces of crankshaft (1) clean with lint-free cloth, and apply lubricating oil.Position crankshaft (1) in engine block (2) with hooks protected with rubber hose or rope sling attwo crank throws and rotate crankshaft (1) until rear crankshaft web is visible.

NOTEUpper thrust rings are not doweled to block. Lower halves aredoweled to No. 7 bearing cap.

Check markings (12) on rear crankshaft web (10) to determine what size upper thrust rings (7) and (8)are to be placed at front or rear of journal (9).Apply lubricating oil to new upper thrust ring (8) and roll in place. Ensure babbit face or groovedside of new upper thrust ring (8) is next to crankshaft flange (11).Wipe new lower bearing shells (5) clean with lint-free cloth and apply lubricating oil.Insert new lower bearing shells (5) over crankshaft (1).

NOTELower thrust ring and No. 7 bearing cap are installed together.Lower thrust ring must be located over dowel on bearing cap.

Apply lubricating oil to new lower thrust ring (8) and position on No. 7 main bearing cap. Ensurebabbit face or grooved side is next to crankshaft flange (11).Wipe wear surfaces of main bearing caps (6) clean with lint-free cloth, and apply coat of lubricatingoil.Position main bearing caps (6) in engine block (2) over new lower bearing shells (5). Ensurenumbers on caps (6) correspond with numbers on engine block (2) on camshaft side.

CAUTION

l Do not tap main bearing caps to seat. Hammering will jarbearing shells out of position and cause engine damage.

l Main bearing screws must be tightened alternately and slowlyto ensure proper seating of bearing caps.

18. Apply lubricating oil to screw (3) threads and new lockplates (4).19. Install new lockplates (4) and fourteen screws (3) through caps (6) in engine block (2).

20. Tighten each screw (3) in three steps of 100 lb-ft (136 N•m) until 300-310 lb-ft (410-423 N•m) isreached.

21. Loosen all screws (3) three turns and repeat step 20.

NOTEDo not bend up tabs on lockplates until after crankshaft endclearance is checked.

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5-55

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d. End Play Clearance

1. Attach dial indicator to rear of engine block (6) with contact point (4) resting on crankshaft endface (3).

2. Push crankshaft end face (3) toward front of engine block (6) and set dial indicator to zero.

3. Push crankshaft end face (3) back toward rear of engine block (6) and check dial indicator,NOTE

Complete steps 4 through 6 only if end clearance of crankshaft isless than 0.007 in. (0.18 mm).

4. Loosen main bearing screws (1) one turn and push crankshaft (2) first toward front, then towardrear of engine block (6).

5. Tighten main bearings screws (1) as in task c, steps 18 through 21.

6. Repeat steps 1 through 3.NOTE

If end clearance is more than 0.22 in. (0.56 mm), crankshaft mustbe replaced or oversize thrust rings installed. Ensure markings onrear crankshaft counterbalance are correct. (Refer to task a, steps11 and 12).

7. Bend up tabs on fourteen lockplates (7) to hold screws (1).

5-56

TM 9-2320-272-24-4


FOLLOW-ON TASK: Install pistons and connecting rods (para. 5-10).

5-57

TM 9-2320-272-24-4

5-9. CAMSHAFT AND GEAR MAINTENANCE

THIS TASK COVERS:

a. Check Backlashb. Removalc. Disassembly

d. Cleaning and Inspectione. Assemblyf. Installation

INITIAL SETUP:


SPECIAL TOOLSTelescoping gauge (Appendix E, Item 136)Cam bushing replacement tool (Appendix E,

Item 26)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Dial indicator (Appendix E, Item 36)Puller kit (Appendix E, Item 102)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)Brass rod

a. Check Backlash

MATERIALS/PARTSSeven cam bushings (Appendix D, Item 34)Camshaft bushing (Appendix D, item 33)Lubricating oil (Appendix C, Item 50)Drycleaning solvent (Appendix C, Item 71)


EQUIPMENT CONDITIONl Engine oil pan removed (para. 4-22).l Piston and connecting rod installed (para. 5-10).

GENERAL SAFETY INSTRUCTIONSl Keep tire extinguisher nearby when using


not use near an open flame.

1. Attach dial indicator to engine block (3) and rotate camshaft gear (2) as far as it will freely moveand hold it in place. Ensure crankshaft gear (1) does not move.

2. Position dial indicator arm to camshaft gear (2) tooth and set dial indicator to zero.

3. Rotate camshaft gear (2) in opposite direction and read backlash measurement as rotation stops. Ifbacklash is not 0.002-0.020 in. (0.05-0.51 mm), replace camshaft gear (2).

NOTENormal backlash is 0.0045-0.0105 in. (0.114-0.267 mm) on newgear with a minimum of 0.002 in. (0.05 mm).

b. Removal

Rotate camshaft gear (2) and camshaft (4) slightly and remove from engine block (3).

CAUTION

Use care when removing camshaft to avoid damaging bearings.

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5-9. CAMSHAFT AND GEAR MAINTENANCE (Contd)

5-59

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c. Disassembly

NOTEBefore disassembling camshaft gear from camshaft, perform taskd of this procedure. If, as a result of inspection, camshaft gearmust be disassembled from camshaft, perform stops 1 through 4.

1. Place camshaft (2) between V-blocks. V-blocks should support camshaft (2).

2. Remove pipe plug (5) from camshaft (2).3. Remove camshaft gear (1) from camshaft (2) with puller.

4. Remove woodruff key (4) and thrust ring (3) from camshaft (2).NOTE

Before removing camshaft bushings from engine block, performtask d of this procedure. If, as a result of inspection, bushingsmust be replaced, perform step 5.

5. Remove seven camshaft bushings (6) from cylinder block (7) with cam bushing replacer.

d. Cleaning and Inspection

1.

2.

3.

4.

5.

WARNING


Clean camshaft (2), camshaft gear (1), and thrust washer (3) with drycleaning solvent and inspectfor cracks, breaks, or pits. If cracked, pitted, or broken, discard.Measure outside diameter of camshaft journals (8) using micrometer. If outside diameter is lessthan 1.996 in. (50.70 mm), replace camshaft (2).Measure thickness of thrust ring (3). If thickness is less than 0.083 in. (2.11 mm), discard thrustring (3).Clean seven camshaft bushings (6) with drycleaning solvent and inspect for breaks, cracks, or pits.If broken, cracked, or pitted, discard.

Measure inner diameter of seven camshaft bushings (6) with telescoping gauge. If inner diameterexceeds 2.001 in. (50.83 mm), discard.

5-60

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5-61

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e. Assembly

Install thrust ring (3), woodruff key (4), camshaft gear (1), and pipe plug (5) in camshaft (2).

f. Installation

CAUTION

Positioning of new camshaft bushing in No. 7 bushing bore (rear ofcylinder block) is critical. The new bushing must be pressed in,leaving clearance between bushing and rear face of cylinder blockto allow oil to drain from hole at rear of camshaft. Hydraulic lockwill occur if oil drain passage is blocked.

NOTENo. 1 cam bushing (gear end) is wider; all others are the same.

1. Position seven cam bushings (7) on cam bushing replacer (6), aligning oil hole (8) in cam bushing (7)to oil hole in main bearing bore.

2. Press seven cam bushings (7) into position in cam bore and check oil hole (8) alignment with a brassrod through main bearing bore oil hole and cam bushing oil hole (8). If brass rod does not passthrough with ease, reposition cam bushings (7).

Use extreme care when installing camshaft to avoid damage tobearings and camshaft lobes.

NOTEAssistant will help with steps 3 through 5.

3. Apply coat of lubricating oil to camshaft lobes (10) on camshaft (2) and camshaft gear (1).4. Position camshaft (2) and camshaft gear (1) in engine block (9) by grasping camshaft gear (1) with

both hands and gently sliding end into cam bore (11). With aid of assistant, carefully guide lobes (10)through bore (11) as camshaft (2) is installed.

5. Align index mark on camshaft gear (1) with index mark on crankshaft gear (12).6. Repeat task a. to check backlash.

5-62

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FOLLOW-ON TASKS: l Replace engine oil pan (para. 4-22).l Install cylinder heads (para. 5-10).

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5-10. PISTON AND CONNECTING ROD MAINTENANCE

THIS TASK COVERS:a. Connecting Rod Side Clearance Checkb. Removalc. Disassembly


INITIAL SETUP:


SPECIAL TOOLSPiston ring groove gauge (Appendix E, Item 97)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 144)Telescoping gauge (Appendix E, Item 136)Outside micrometer (Appendix E, Item 80)Inside micrometer (Appendix E, Item 82)Piston ring expander (Appendix E, Item 96)Arbor pressFeeler gaugeSoft-faced hammerViseTape-protected tool

a. Connecting Rod Side Clearance Check

1.

2.

3.

MATERIALS/PARTSTwelve bearing shells (Appendix D, Item 14)


EQUIPMENT CONDITIONCamshaft and gear removed (para. 5-9).

GENERAL SAFETY INSTRUCTIONSGloves must be worn when handling hot pistons.

NOTEConnecting rod should have free movement at crank journal.Check with hand pressure first. Tap lightly with soft-facedhammer only if necessary.

Move connecting rod (1) up and down on crank journal (3) and measure clearance with feeler gauge.Clearance should be 0.0045-0.13 in. (0.11-0.33 mm). Record clearance of all six connecting rods forreassembly.

NOTEIf clearance is not 0.0045-0.13 in. (0.11-0.33 mm) or rod will notmove, continue with steps 2 and 3.

Remove cap (2) and check for improper bearing size, dirt, or burrs.

Install cap (2) as outlined in task f.

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5-10. PISTON AND CONNECTING ROD MAINTENANCE (Contd)

5-65

TM 9-2320-272-24-4


1. Place cylinder block (1) in vertical position and remove all carbon from upper inside wall of eachcylinder liner. Use ridge reamer as necessary.

NOTEAll six connecting rod and bearing caps are removed the same way.Steps 2 through 5 are for one connecting rod and bearing cap only.

2. Rotate crankshaft (3) until connecting rod bearing caps (5) are above edge of cylinder block flange (2).3. Loosen two screws (6) on connecting rod bearing cap (5) 3/8 in. (9.5 mm) and tap with soft-faced

hammer to free connecting rod bearing cap (5) from connecting rod (7).NOTE

l Tag and mark bearing cap for installation.l Do not mix bearing caps.

4. Remove two screws (6), bearing cap (5), and lower half bearing shell (4) from connecting rod (7).Discard lower half bearing shell (4).

CAUTION

Use a tape-protected tool to push piston from block. Failure to dothis may result in damage to cylinder liners.

NOTEl Assistant will help with steps 5 and 6.l Mark location and position of all pistons before removal from

block. Discard upper half bearing shells.

5. Push connecting rods (7), pistons (8), and upper bearing shells (9) out of cylinder block (1) with tape-protected tool. Begin at crankshaft (3) side.

CAUTION

Bearing caps and connecting rods are stamped with same numberas the cylinder. Mixing piston assemblies may cause equipmentdamage.

6. After each piston (8) and connecting rod (7) is removed, assemble connecting rod bearing cap (5) toconnecting rod (7) with two screws (6).

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c. Disassembly

1. Remove four piston rings (1) from piston (6).2. Remove two snaprings (2) from piston pin bore (5).

WARNING

Pistons must be heated in hot water to remove piston pins. Do nothandle hot pistons with bare hands. Use protective gloves to avoidburning hands.

NOTEMark piston and connecting rod so it can be reassembly in samemanner.

3. Submerge pistons (6) and connecting rod (4) assemblies in container of hot water for fifteen minutesto allow pistons to expand.

4. Remove pistons (6) and connecting rod (4) assemblies from hot water with tongs or hook and placein vise. Push piston pin (3) out of piston pin bore (5). Do not drive pins (3) out with hammer.

5. Place pistons (6), piston pins (3), and connecting rods (4) on a numbered rack and hold forinspection.


NOTEEnsure bearing caps remain assembled to mating connecting rodsat all times to avoid mixing.

1. Clean connecting rod assemblies (7) (para. 2-14).

2. Inspect connect rod assemblies (7) (para. 2-15).3. Visually check I-beam section (8) of connecting rod (4) for nicks, dents, and gouges. If nicks, dents,

or gouges are greater than 0.031 in. (0.787 mm), replace connecting rod (4).

4. Inspect connecting rod assemblies (7) for cracks (para. 2-16).NOTE

To accurately measure all connecting rod bearing cap bores, the screwsmust be tightened to the operating torque specified in table 5-7.

5. Install bearing caps (9) on connecting rod (4) with screws (10).6. Alternately tighten screws (10) with torque wrench in accordance with the sequence order in

table 5-7.Table 5-7. Connecting Rod Screw Tightening Sequence.

TIGHTEN SEQUENCE TORQUE VALUESLB-FT N•M

Step l-Tighten to 70-75 (95-102)

Step 2-Tighten to 140-150 (90-203)

Step 3-Loosen to (0) (0)

Step 4-Tighten to 25-30 (34-41)

Step 5-Advance to 70-75 (95-102)

Step C--Advance to 140-150 (190-203)

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7. Using telescoping gauge, measure inside diameter of crankshaft. journal bore (2) in connectingrod (1) at points A-A and B-B, up to 30° either side of parting line C. Record readings. If crankshaftjournal bore (2) diameter is not 3.2725-3.2730 in. (83.122-83.134 mm), replace connecting rod (1).

8. Using telescoping gauge, measure inside diameter of crankshaft journal bore (2) in connecting rodat points D-D and E-E. Record readings. If crankshaft journal bore (2) diameter is not 3.2725-3.2730in. (83.122-83.134 mm), replace connecting rod (1).

NOTECheck pin bores with bushings installed.

9. Check inside diameter of piston pin bushing bore (6) in connecting rod (1) with telescoping gauge. Ifpiston pin bushing bore (6) is worn beyond 2.0022 in. (50.856 mm), mark bushings for replacement.

NOTEl Pistons must be cleaned before inspection.l Conditions of the pistons and piston rings should be carefully

noted, as ‘they indicate borderline conditions leading to enginefailures.

l Pistons should be inspected at ambient temperatures of 70°-90°F (21°-32°C).

10. Check piston (5) wear surface for scoring, scuffing, and cracks. If scored, scuffed, or cracked, replacepiston (5).

NOTEVertical scratching and discoloration of piston ring sealing surfaceis a major cause of oil consumption and piston and liner scoring.

11. Check piston rings (3) for vertical scratching and discoloration of piston ring sealing surface. If ringsealing surface is scratched or discolored, replace piston rings (3).

12. Check for broken piston rings (3). If broken, replace piston ring (3).13. Check piston rings (3) for formation of deposits which prevent outward movement of piston rings (3) to

seal. If piston ring (3) sticks in piston grooves, replace piston ring (3).14. Check piston pin bore (4) on piston (5) for fractures. If piston ring bore (4) is fractured, replace

piston (5).NOTE

l Pistons must be inspected at ambient temperatures of 70°-90°F(21°-32°C) to obtain accurate measurement readings.

l First and second piston ring grooves are checked for depth wearthe same way. Step 15 checks for ring groove depth wear on thetop ring groove.

15. Insert ring groove gauge into top ring groove (7) of pistons (5) and note whether shoulders (6) ofgauge touch ring groove (7). If shoulders (6) of gauge touch either ring groove (7), pistons (5) are notserviceable and must be discarded.

16. Repeat step 15 for second ring groove (8).

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NOTEFirst and second piston ring groove widths are checked for wearthe same way. Step 17 checks top ring groove width for wear.

17. Place and hold new piston ring (2) in top ring groove (3) and try to insert 0.006 in. (0.15 mm) feelergauge into ring groove (3) at top of piston ring (2). If feeler gauge enters either ring groove (3)without force, piston (1) is not serviceable and must be discarded.

18. Repeat step 17 for second ring groove (4).NOTE

Measurements to check piston skirt outside diameters are takenat right angle to piston bore.

19. Measure piston (1) upper skirt outside diameter (6) approximately 1 in. (25.4 mm) below bottomring groove (4) with micrometer.

20. Measure piston (1) bottom skirt outside diameter (7) approximately 1 in. (25.4 mm) above skirt bottom (8).If outside diameters (6) and (7) measure less than 5.483 in. (139.27 mm), discard piston (1).

21. Measure piston pin bore (5) inside diameter. If inside diameter exceeds 1.99 in. (50.775 mm) at 70°F(21°C), discard piston (1). Add .0005 in. (0.13 mm) per each 10°F over 70°F (21°C) up to 90°F (32°C).

22. Check outside diameter of piston pin (9) with micrometer. If outside diameter is worn out-of-roundmore than 0.001 in. (0.03 mm), discard piston pin (9). If diameter is smaller than 1.99885 in.(50.762 mm), discard piston pin (9).

23. Check all piston (1) parts to be sure they are numbered the same. Number is generally located onthe inside of piston (1) skirt.

NOTENew piston rings must be checked in the cylinder liner in whichthey will be used to ensure ring gaps are correct.

24. Insert piston rings (11), (13), (14), and (15) in each mating cylinder liner (10) bore, using head (top)of piston (1) to position piston ring (11) so it seats squarely in piston ring (11) travel area.

25. Measure ring gap (12) with feeler gauge. Ring gap (12) should meet specifications given intable 5-8.

NOTEAdd 0.003 in. (0.08 mm) ring gap to new maximum for each 0.001in. (0.03 mm) wear in cylinder liner wall. Measurement made inring travel area of liner.

Table 5-8. Ring Gap.

No. 1 compression ring (13) gap 0.023-0.033 in.(0.58-0.85 mm)

No. 2 and 3 compression ring (11) and (14) gap 0.019-0.029 in.(0.48-0.74 mm)

No. 4 oil ring (15) gap 0.010-0.025 in.(0.25-0.64 mm)

26. Install piston rings (13), (11), (14), and (15) in piston (1) with piston ring expander. Ensure the word“top” faces toward top of piston (1).

27. Check connecting rod journals (17) on crankshaft assembly (16) for scores and scratches. If scored orscratched, replace crankshaft.

28. Check connecting rod journals (17) for out-of round wear with micrometer. If worn more than 0.002in. (0.05 mm), replace crankshaft.

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1. Remove piston pin bushing (10) from connecting rod (5) with mandrel, removal tool, and arbor press.2. Install sleeve (6), new standard size piston pin bushing (10), and guide sleeve (8) on mandrel.3. Place connecting rod (5) on block (7) and place in horizontal position.4. Line up mark on guide sleeve (8) with middle of boss on connecting rod (5). Ensure oil hole in new

piston pin bushing (10) and pin bore (9) are lined up.

5. Press new piston pin bushing (10) into pin bore (9) with arbor press until guide sleeve (8) contactsside of rod pin boss.

6. Check inside diameter of new piston rod bushing (10). If inside diameter is not 2.001-2.0015 in.(50.83-50.838 mm), replace piston pin bushing (10).

WARNING

Do not handle hot pistons with bare hands or injury to personnelmay result.

CAUTIONNever drive piston pins into pistons. Driving may cause distortionof piston and cause piston seizure in cylinder liner.

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NOTEl Ensure rod and bearing cap are stamped with the numbers of

the cylinders they were removed from. All pistons must havesame part number.

l Ensure pistons and connecting rods are assembled withorientation marks matching.

7. Install one piston pin snapring (1) in groove of piston pin bore (2).

8. Heat pistons (3) in hot water.CAUTION

Do not attempt to install pin after piston has cooled. Pin will not fit.

9. Install piston pin (4) through piston (3) and connecting rod (5) pin bores (9) before piston (3) cools.10. Install second snapring (1) in piston pin (4) groove at opposite end of pin bore (2).

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f. Installation

1.2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

NOTEl Before installation, ensure all pistons have been properly

assembled and lubricated.l If old pistons are being installed, ensure they are installed in

same location from which they were removed.

Remove two screws (5) and rod cap (4) from connecting rod (2).Apply coat of lubricating oil to piston (1), connecting rod (2), and upper bearing shell (3).

Position tang (6) on new bearing (3) to groove (7) in connecting rod (2) and snap into place.NOTE

Ensure piston ring gaps are staggered so they are not in line witheach other or piston pin.

Position ring compressor (10) over piston (1) and tighten with Allen wrench.CAUTION

Assistant must guide connecting rod through cylinder from oil panside of block to avoid damaging liner.

NOTEEnsure numbered side of connecting rod is toward the camshaftside of engine block.

Carefully insert connecting rod (2) in cylinder liner (9) and hold ring compressor (10) right andfirmly seated against engine block (8). Ensure crankshaft journal (12) is at bottom dead center.

CAUTION

l Ring compressor must be held firmly against engine block toprevent compressor from sipping and causing piston ringbreakage when pushing piston into cylinder liner.

l Do not force piston assembly into liner. If piston does not installfreely in liner, remove and check for broken rings.

NOTEAssistant will guide rod onto crankshaft journal to preventdamage to journal and liner.

Push piston (1) through ring compressor (10) until all piston rings are well into cylinder liner (9) inengine block (8).

Drive piston (1) and rod (2) into cylinder liner (9) with rubber or wooden mallet handle until upperrod bearing shell (3) seats on crankshaft journal (12).

Apply lubricating oil to lower connecting rod bearing shell (11).Position new bearing shell (11) in rod cap (4) and install rod cap (4) so numbered side is matched tonumbered side of rod (2). Ensure tang (6) on bearing shell (11) is aligned with groove in rod cap (4).Apply lubricating oil to screw (5) threads and install screws (5) through rod cap (4) and tighten(table 5-7).Check connecting rod clearance by following task a.

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FOLLOW-ON TASK: Install camshaft and gear (para. 5-9).

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5-11. ENGINE OIL PUMP REPAIR

THIS TASK COVERS:

a. Disassemblyb. Cleaning and Inspection

c. Repaird. Assembly

INITIAL SETUP:


TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Telescoping gauge (Appendix E, Item 136)Snap gauge (Appendix E, Item 123)Boring tool (Appendix E, Item 18)Torque wrench (Appendix E, Item 144)Soft-faced hammerArbor press

MATERIALS/PARTSBypass seat (Appendix D, Item 29)Bypass spring (Appendix D, Item 30)Bypass disc (Appendix D, Item 28)Lockplate (Appendix D, Item 339)Gasket (Appendix D, Item 176)Two dowel pins (Appendix D, Item 96)Two screw-assembled lockwashers

(Appendix D, Item 590)Two gaskets (Appendix D, Item 174)Seven lockwashers (Appendix D, Item 354)Spring (Appendix D, Item 668)Three lockwashers (Appendix D, Item 364)Lubricating oil (Appendix C, Item 50)Antiseize tape (Appendix C, Item 72)Drycleaning solvent (Appendix C, Item 71)

a. Disassembly


EQUIPMENT CONDITIONl Engine oil filter removed (para. 3-5).l Engine front gearcase cover removed (para. 4-18).l Engine accessory drive removed (para. 4-26).l Engine oil pump removed (para. 4-21).

GENERAL SAFETY INSTRUCTIONSl Keep tire extinguisher nearby when using


not use near an open flame.l When cleaning with compressed air, wear

eyeshields and ensure source pressure does notexceed 30 psi (207 kPa).

1. Remove adapter (7), elbow (8), and nipple (6) from oil pump body flange (1).2. Remove elbow (9) and nipple (10) from oil pump body flange (1).

3. Remove pipe plugs (11) and (12) from oil pump body flange (1).4. Remove pipe plug (5) from inner body (2).5. Remove pipe plug (3) from filter head (4).

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5-11. ENGINE OIL PUMP REPAIR (Contd)

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6. Remove two screw-assembled lockwashers (12), flange plate (11), and gasket (10) from inner body (9).Discard gasket (10) and screw-assembled lockwashers (12).

7. Hold retainer (14) down and remove screw (1) from oil pump body (13).8. Slowly release retainer (14) and remove lockwasher (16), lockplate (15), retainer (14), retainer cap (2),

spring (3), and regulator plunger (4) from oil pump body (13). Discard lockwasher (16), lockplate (15),and spring (3).

9. Remove bypass seat (6), disc (7), and bypass spring (8) from filter head (5). Discard bypass seat (6)and bypass spring (8).

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10.11.

12.

13.14.15.

16.

17.18.19.

20.21.

22.23.

Remove two screws (6) and lockwashers (5) from filter head (1). Discard lockwashers (5).Remove six screws (7) and lockwashers (8) from filter head (1). Discard lockwashers (8).

Tap filter head (1) with soft-faced hammer to separate from dowel pin (4) and inner body (3) andremove filter head (1) and gasket (2) from inner body (3). Discard gasket (2).Clean gasket remains from mating surfaces of filter head (1) and inner body (3).Remove idler gear (14) from idler shaft (15) and inner body (3).Press driveshaft (10) through driven gear (13) with arbor press and remove driven gear (13) fromdriveshaft (10).Tap inner body (3) and gasket (12) with soft-faced hammer to separate from dowel pin (11) andremove inner body (3) and gasket (12) from oil pump body (9). Discard gasket (12).

Clean gasket remains from mating surfaces of oil pump body (9), inner body (3), and gasket (12).Remove idler gear (17) from idler shaft (15).Press driveshaft (10) through driven gear (15) with arbor press and remove driven gear (15) fromdriveshaft (10).Remove drive gear (18) from driveshaft (10) with arbor press.Remove idler shaft (15) from oil pump body (9) with arbor press.

NOTEPerform steps 22 and 23 only if dowel pins are damaged.

Remove dowel pin (4) from inner body (3). Discard dowel pin (4).Remove dowel pin (11) from oil pump body (9). Discard dowel pin (11).

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1.

2.

3.4.

5.6.7.8.

9.10.11.12.

13.

14.

15.

16.

17.

18.

WARNING

l Drycleaning solvent is flammable and toxic. Do not use nearopen flame and always have a fire extinguisher nearby whensolvents are used. Use only in well-ventilated places, wearprotective clothing, and dispose of cleaning rags in approvedcontainer. Failure to do this may result in injury or death topersonnel and/or damage to equipment.

l Eyeshields must be worn when cleaning with compressed air.Compressed air source will not exceed 30 psi (207 kPa). Failureto do so may result in injury to personnel.

Wipe pump body (2) clean with drycleaning solvent.

Blow out pump body (2) oil passages with compressed air.

Inspect pump body (2) for breaks and cracks. Replace if broken or cracked.Check inside bore diameter of front and rear driveshaft bushings (1). Replace front and rear driveshaft bushings (1) if inside diameter exceeds 0.6185 in. (15.710 mm).Wipe filter head (5) clean with drycleaning solvent.Blow out filter head (5) oil passages with compressed air.Inspect filter head (5) for breaks and cracks. Replace filter head (5) if broken or cracked.Check inside diameter of filter head bushing (4) for wear with dial bore gauge. Replace bushing (4) ifinner diameter exceeds 0.6185 in. (15.710 mm).

Wipe inner body (3) clean with drycleaning solvent.Blow out inner body (3) oil passages with compressed air.Inspect inner body (3) for breaks and cracks. Replace inner body (3) if broken or cracked.Clean drive gear (11), two driven gears (9), and two idler gears (8) with drycleaning solvent, andinspect for cracked, chipped, or broken teeth. Replace gears if gears (11), (8), and (9) teeth arecracked, chipped, or broken. Replace gears (11), (8), and (9) if gear teeth show pitting over morethan 1/4 width of active tooth area.

Clean two idler gears (8) and four bushings (10) with drycleaning solvent.

Check inside diameter of two idler gears (8) and four bushings (10) with bore gauge. Replace idlergears (8) and bushings (10) if inner diameter exceeds 0.6185 in. (15.71 mm).Inspect pressure regulator plunger (6) to ensure it does not bind in bore (7) of oil pump body (2).Replace pressure regulator plunger (6) if bent or binds.Clean idler shaft (12) and driveshaft (13) with drycleaning solvent.Inspect idler shaft (12) and driveshaft (13) for breaks, cracks, and galling. Replace if broken,cracked, or galled.Check idler shaft (12) and driveshaft (13) outside diameters using dial snap gauge. Replace shafts (12)and (13) if outside diameters are less than 0.6145 in. (15.608 mm).

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1.

2.

3.

4.

5.6.7.

8.9.

NOTEl Steps 1 through 9 are performed to replace parts found defective

during cleaning and inspection steps 3, 7, 12, and 13.l Bushings must be replaced as a pair.

Using arbor press and mandrel, remove old front and rear driveshaft bushings (2) from oil pumpbody (1).Install new front and rear driveshaft bushings (2) in oil pump body (1), flush to 0.030 in. (0.78 mm)below surfaces.Bore new front and rear driveshaft bushings (2) inner diameter to 0.6165-0.6175 in. (15.659-15.684 mm).

Remove old bushing (3) from filter head (4).

Install new bushing (3) in filter head (4) to 0.020 in (0.51 mm) below front surface.Bore new bushing (3) inner diameter to 0.6165-0.6175 in. (15.659-15.684 mm).Using arbor press and mandrel, remove four old bushings (6) from two idler gears (5).

NOTEIdler gear bushings must be replaced as a pair.

Press two new bushings (6) in each idler gear (5) flush to 0.20 in. (0.51 mm) below gear face.Bore inner diameter of four bushings (6) to 0.6165-0.6175 in. (15.659-15.684 mm).

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1.

2.

3.4.

5.6.7.8.

9.

10.

11.

12.

13.

Press drilled end of idler shaft (3) into gear pocket side of oil pump body (1) with arbor press andmandrel until idler shaft (3) protrudes 2.604-2.620 in. (66.04-66.55 mm) above back of body.Press drive gear (5) over drilled end of driveshaft (2) with arbor press and mandrel until driveshaft. (2)end protrudes 0.040-0.060 in. (1.02-1.52 mm) above drive gear (5) face.Apply lubricating oil to driveshaft (2) and insert driveshaft (2) into oil pump body (1).Position 0.012 in. (0.20 mm) shim (4) between back side of drive gear (5) and front of oil pump body (1)and install drive gear (5) against shim (4) until snug. Remove shim (4).

NOTEPerform step 5 only if dowel pin was removed during disassemblyprocedure.

Install new dowel pin (7) in oil pump body (1) to 0.990-1.010 in. (22.15-25.65 mm) above face.Install idler gear (10) on idler shaft (3).Press driven gear (6) on driveshaft (2) with arbor press and mandrel.Position 0.012 in. (0.30 mm) shim (4) on rear surface of driver gear (6) facing inner body (9) andposition inner body (9) over shafts (2) and (3) so it rests on the shim. Install inner body (9) to seatdriven gear (6) and remove inner body (9) and shim (4).

Apply lubricating oil to gears (6) and (10), shafts (3) and (2), and gear pockets.Install new gasket (8) and inner body (9) on pump body (1), using soft-faced hammer to seat innerbody (9) on dowel pin (7). Ensure screw holes are open.

NOTEPerform step 11 only if dowel pin was removed during disassemblyprocedure.

Install new dowel pin (11) in inner body (9) to 0.990-1.010 in. (25.15 to 25.65 mm) above face.

Press driven gear (6) on driveshaft (2) with arbor press and mandrel. Leave 0.002-0.004 in.(0.05-0.10 mm) clearance between bottom of gear pocket and driver gear (6) surface.

Install idler gear (10) on idler shaft (3).

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14. Apply lubricating oil to gears (6) and (10), shafts (2) and (3), and gear pockets.

NOTEScrew is an installation screw and cannot be tightened at thistime.

15. Position screw (14) and new lockwasher (15) in inner body (9).16. Install new gasket (12) and filter head (13) on inner body (9) with two screws (17), new lockwashers

(16), six screws (18), and new lockwashers (19). Use soft-faced hammer to seat filter head (13). Tightenscrews (17) and (18) 30-35 lb-ft (41-47 N•m).

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17.18.19.

20.21.

22.

Rotate drive gear (17) back and forth to ensure inner gears are free.Check driveshaft (18) end play. End play must be 0.004-0.007 in. (0.10-0.18 mm).Install pressure regulator plunger (15), new spring (5), and retainer cap (4) in pump body (14) withretainer clamp (16), new lockplate (3), new lockwasher (2), and screw (1). Tighten screw (1)30-35 lb-ft (41-47 N•m).

Bend tabs of lockplate (3) with hammer and drift punch.Install new bypass spring (7), disc (9), and new bypass seat (8) in filter head assembly (6).

Install new oil pump flange gasket (11) and flange (12) on pump flange (10) with two newlockwashers (14) and screw-assembled washers (13).

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FOLLOW-ON TASKS: l Replace engine oil filter (para. 3-5).l Install engine accessory drive (para. 4-26).l Install engine front gearcase cover (para. 4-18).l Install engine oil pump (para. 4-21).

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5-12. MOUNTING FUEL PUMP TO HOLDING FIXTURE

THIS TASK COVERS:a. Removal b. Installation

INITIAL SETUP:

APPLICABLE MODELS REFERENCES (TM)M939/A1 TM 9-2320-272-24P

SPECIAL TOOLSMounting plate (Appendix E, Item 84)Ball joint vise (Appendix E, Item 7)

TOOLSGeneral mechanic’s tool kit (Appendix E. Item 1)

EQUIPMENT CONDITIONl Fuel pump removed from engine (para. 4-35).l Fuel pump shutoff valve removed (para. 4-36 or

4-37).

1. Remove two nuts (2), screws (5), and fuel pump (3) from mounting plate (1).2. Remove two screws (4) and mounting plate (1) from ball joint vise.

1. Attach mounting plate (1) to ball joint vise and install two screws (4).

2. Install fuel pump (3) to mounting plate (1) with two screws (5) and nuts (2).

FOLLOW-ON TASKS: l Install fuel pump on engine (para. 4-35).l Install fuel pump shutoff valve (para. 4-36 or 4-37).

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5-13. PRESSURE GEAR PUMP REMOVAL

THIS TASK COVERS:Removal

INITIAL SETUP:

APPLICABLE MODELS MATERIALS/PARTSM939/A1 Two lockwashers (Appendix D, Item 407)

TOOLS REFERENCES (TM)General mechanic’s tool kit (Appendix E, Item 1) TM 9-2320-272-24PSoft-faced hammer

Removal

1.

2.

3.4.5.6.

Remove two screws (4), lockwashers (3), washers (2), pulsation damper (1), and seal (5) from gearpump (8). Discard lockwashers (3).

Remove four screws (10) and lockwashers (9) connecting gear pump (8) to fuel pump housing (6).Discard lockwashers (9).Tap gear pump (8) lightly with soft-faced hammer and remove from fuel pump housing (6).Remove gasket (7) from gear pump (8). Discard gasket (7).Clean gasket remains from gear pump (8) mating surfaces.Install seal (5) and pulsation damper (1) on fuel pump housing (6) with two washers (2), newlockwashers (3), and screws (4).

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5-14. GOVERNOR SPRING PACK MAINTENANCE

THIS TASK COVERS:a. Removal c. Installationb. Inspection

INITIAL SETUP:


TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1)Spring tester (Appendix E, Item 131)

Fuel pump mounted on holding fixture (para. 5-12).

MATERIALS/PARTSRetaining ring (Appendix D, Item 538)Gasket (Appendix D, Item 223)Seal (Appendix D, Item 612)

NOTESpring packs are maintained basically the same for AFC andVS fuel pumps. This procedure covers the AFC fuel pump.

a. Removal

1. Remove seal (12) from governor adjusting screw (13) and throttle leakage adjusting screw (18).Discard seal (12).

2. Remove four screws (14), spring pack cover (15), and gasket (16) from fuel pump (1). Discardgasket (16).

3. Remove retaining ring (11), spring retainer (10), shim(s) (9), spring (8), spring guide (5), washer (4),spring (3), and plunger (2) from spring pack barrel (17). Discard retaining ring (11).

4. Remove adjusting screw (7) and spring (6) from spring guide (5).

b. Inspection

1. For general inspection instructions, refer to para. 2-15.2. Inspect spring pack cover (15) for cracks, breaks, and stripped threads. Replace spring pack cover (15)

if cracked, broken, or threads are stripped.3. Using spring tester, inspect tension of spring (8). Replace spring (8) if tension is not within 0.69-0.85 lb

(0.31-0.39 kg) when compressed to 1.0 in. (25.4 mm).4. Using spring tester, inspect tension of spring (3). Replace spring (3) if tension is not within 16.02-

17.78 lb (7.27-8.07 kg) when compressed to 1.025 in. (26.0 mm).

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5-14. GOVERNOR SPRING PACK MAINTENANCE (Contd)

c. Installation

1. Install spring (6) and adjusting screw (7) on spring guide (5).

2. Install plunger (2), spring (3), washer (4), spring guide (5), spring (8), shim(s) (9), and springretainer (10) on spring pack barrel (17) with new retaining ring (11).

3. Install new gasket (16) and spring pack cover (15) on fuel pump (1) with four screws (14).

NOTESeal is not installed until fuel pump calibration (para. 5-18).

FOLLOW-ON TASKS: l Remove fuel pump from holding fixture (para 5-12).l Calibrate fuel pump (para. 5-18).

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5-15. FUEL PUMP HOUSING MAINTENANCE

THIS TASK COVERS:

a. Disassemblyb. Inspection

c. Assembly

INITIAL SETUP:


TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1) l Governor spring pack removed (para. 5-14).

MATERIALS/PARTSl Throttle shaft removed (para. 5-16).

Seven lockwashers (Appendix D, Item 412)Gasket (Appendix D, Item 239)Diesel fuel (Appendix C, Item 41)

a. Disassembly

NOTETap edge of hardware lightly with soft-faced hammer to loosen,

1. Remove screw (7), six screws (1), seven lockwashers (2), and washers (3) connecting front drivecover (6) to fuel pump housing (4). Discard lockwashers (2).

2. Pull fuel pump housing (4) straight out from front drive cover (6) to clear dowels.3. Remove gasket (5) from front drive cover (6). Discard gasket (5).4. Clean gasket remains from front drive cover (6) mating surfaces.

5. Remove governor plunger (9) and torque spring (8) from fuel pump housing (4).

NOTEDo not use straight pull on governor plunger torque spring. Toremove, twist spring off shoulder.

6. Remove torque spring (8) from governor plunger (9).

b. Inspection

1. Inspect governor plunger (9) for scoring, nicks, and scratches. If scored, nicked, or scratched, replacegovernor plunger (9).

2. Inspect torque spring (8) for broken coils. If coils are broken, replace torque spring (8).

c. Assembly

NOTEParts must submerged in diesel fuel and hands wet with dieselfuel before steps 1 and 2 to prevent damage to close-toleranceparts.

1. Install torque spring (8) on governor plunger (9).

2. Install torque spring (8) and governor plunger (9) in fuel pump housing (4).3. Install new gasket (5) and fuel pump housing (4) on front drive cover (6) with seven washers (3),

new lockwashers (2), six screws (1), and screw (7).

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5-15. FUEL PUMP HOUSING MAINTENANCE (Contd)

FOLLOW-ON TASKS: l Install throttle cover and shaft (para. 5-16).l Install governor spring pack (para. 5-14).

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5-16. THROTTLE COVER AND SHAFT MAINTENANCE

THIS TASK COVERS:a. Disassemblyb. Inspection

c. Assembly

INITIAL SETUP:


TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1) Fuel pump housing disassembled (para. 5-15).

MATERIALS/PARTSTwo drive pins (Appendix D, Item 101)O-ring (Appendix D, Item 461)O-ring (Appendix D, Item 462)O-ring (Appendix D, Item 463)Lockwasher (Appendix D, Item 400)Throttle shaft soft ball bearing (Appendix D,

Item 666)

a. Disassembly

1. Center punch and drill out the two drive pins (8) connecting the fuel pump housing (1) to throttleshaft cover (2). Discard drive pins (8).

2. Remove nut (4), lockwasher (5), washer (6), screw (7), throttle lever (3), and throttle shaft cover (2)from fuel pump housing (1). Discard lockwasher (5).

3. Remove retaining ring (10) and throttle shaft (9) from fuel pump housing (1).

4. Drill and remove soft ball bearing (18) from throttle shaft (9). Discard soft ball bearing (18).5. Remove two set screws (15) and throttle stop control (14) from throttle shaft (9).6. Remove O-rings (13) and (16), fuel-adjust screw (17), valve plug (12), and O-ring (11) from throttle

shaft (9). Discard O-rings (13), (16), and (11).

b. Inspection

1. Inspect throttle shaft (9) for scoring, nicks, and scratches. If scored, nicked, or scratched, replacethrottle shaft (9).

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5-16. THROTTLE COVER AND SHAFT MAINTENANCE (Contd)

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c. Assembly

1.

2.

3.4.

5.

6.

7.

8.

9.

NOTEGovernor weight must be installed before assembling throttleshaft cover (para. 5-17).

Install new O-ring (11) and valve plug (12) in fuel pump housing (1).

Install fuel-adjusting screw (17), new O-rings (13) and (16), throttle stop control (14) and twosetscrews (15) on throttle shaft (9).Install new throttle shaft ball (18) in end of throttle shaft (9).Install throttle shaft (9) in fuel pump housing (1) with retaining ring (10).

NOTEl Do not install throttle shaft cover until fuel pump has been

calibrated (para. 5-18).l Do not perform steps 5 through 7 unless pin holes are damaged

beyond use.Position throttle shaft cover (2) on fuel pump housing (1).

CAUTION

Use care when drilling new holes for drive pins. The pumphousing is made of cast aluminum and is easily damaged. Do notallow metal particles to enter pump housing.

Center punch location of new holes on throttle shaft cover (2). Ensure holes are opposite oneanother.

Carefully drill through throttle shaft cover (2) and into throttle shaft cover flange with 1/15 in. drillbit NO MORE than 1/4 in. (6 mm).Install throttle shaft cover (2) on fuel pump housing (1) by gently tapping two new drive pins (8)through throttle shaft cover (2) into holes.Install throttle lever (3) on throttle shaft (9) with screw (7), washer (6), new lockwasher (5), andnut (4).

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FOLLOW-ON TASK: Assemble fuel pump housing (para. 5-15).

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5-17. GOVERNOR WEIGHT MAINTENANCE

THIS TASK COVERS:a. Removal c. Installationb. Inspection

INITIAL SETUP:


TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1) Throttle cover and shaft disassembled (para. 5-16).

a. Removal

1. Remove governor weight (6) and gear (2) from front drive cover (1).2. Remove weight-assist plunger (5), spring (3), and shims (4) from governor weight (6).

b. Inspection

1. Inspect spring (3) for bent or broken coils. If bent or broken, replace spring (3).2. Inspect governor weight gear (2) for cracked, broken, or pitted teeth. If cracked, broken, or pitted,

replace governor weight (6).

c. Installation

1. Install shims (4), spring (3), and weight-assist plunger (5) in governor weight (6).NOTE

Large end of weight-assist plunger is installed first.

2. Install governor weight gear (2) and governor weight (6) on front drive cover (1).

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5-17. GOVERNOR WEIGHT MAINTENANCE (Contd)

FOLLOW-ON TASKS: l Install front cover (para. 5-15)l Install throttle shaft and cover (para. 5-16).

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5-18. FUEL PUMP SETUP AND CALIBRATION

THIS TASK COVERS:a. Throttle Shaft Cover Removal i. Testing and Adjusting Pump Main Pressureb. Mounting Pump to Test Stand j. Testing and Adjusting Fuel Pressurec. Fuel Pump Run-In k. Testing and Adjusting Governor Fueld. Testing Pump Seals for Leaks Pressuree. Testing Governor Cutoff RPM l. Checking and Adjusting Governor Weightf. Testing and Adjusting Throttle Leakage Pressureg. Testing and Adjusting Idle Speed m. Testing and Adjusting Idle Speedh. Checking and Adjusting Throttle Lever (VS Governor Only)

Travel n. Shutdown and Removal from Test Stand

INITIAL SETUP:


SPECIAL TOOLSFuel injection tester (test stand) (Appendix E,

Item 49)Spring pack adjusting tool (Appendix E,

Item 130)Travel template (Appendix E, Item 150)Level and angle indicator (Appendix E, Item 66)Shaft installation tool (Appendix E, Item 120)Gear pump block plate (Appendix E, Item 57)

TOOLSGeneral mechanic’s tool kit (Appendix E,

Item 1)Straightedge

MATERIALS/PARTSTwo drive pins (Appendix D, Item 101)Lockwasher (Appendix D, Item 400)Throttle shaft soft ball bearing (Appendix D,

Item 666)Grease, GAA (Appendix C, Item 28)Lubricating oil OE/HDO 30 (Appendix C, Item 50)45A calibrating fluid (Appendix C, Item 13)Sealing tape (Appendix C, Item 72)

REFERENCES (TM)TM 9-2320-272-24PTM 9-4910-571-12TM 9-4910-571-12P

EQUIPMENT CONDITIONl Fuel pump removed from vehicle (para. 4-35).l Fuel pump shutoff valve removed (para. 4-36 or

4-37).

a. Throttle Shaft Cover Removal

NOTEPerform task a. only if throttle shaft cover has not been removed.

1. Center punch each of the two drive pins (8) connecting throttle shaft cover (2) to fuel pump housing (1).2. Drill drive pins (8) out of throttle shaft cover (2). Discard drive pins (8).

3. Remove nut (4), lockwasher (5), washer (6), screw (7), and throttle lever (3) from throttle shaft cover (2).Discard lockwasher (5).

4. Remove throttle shaft cover (2) from fuel pump housing (1).5. Install throttle lever (3) on fuel pump housing (1) with washer (6), new lockwasher (5), and nut (4).

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5-18. FUEL PUMP SETUP AND CALIBRATION (Contd)

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b. Mounting Pump to Test Stand

1.

2.

3.

4.5.

6.7.

8.9.

10.11.

12.

13.

14.

15.

16.

17.

18.

Install adapter ring (7) on adapter bracket (8) with four washers (9) and screws (6). Ensure theword TOP or part number on adapter ring (7) faces up.Install ring and adapter bracket (4) on mounting rails (16) of test stand with clamp bar (14).Tighten clamp bar (14) finger tight.Mount fuel pump (11) to ring and adapter bracket (4) with four screws (12) and washers (13).Place pump coupling insert (15) into test stand drive coupling (10).

Loosen clamp bar (14) and slide fuel pump (11) and ring and adapter bracket (4) forward to engagedrive coupling (10).

NOTEClean all male pipe threads and wrap with sealing tape beforeinstallation.

Install inlet adapter (27) on pump elbow (26).Connect 1/2 in. (12.7 mm) flexible hose (30) from test stand fuel pressure control valve (32) toadapter (27).Connect 1/4 in. (6.35 mm) manifold hose (24) from manifold vacuum adapter (28) to adapter (21).Install pump discharge fitting (18) in fuel pump shutoff solenoid valve (19).Install fuel pressure hose (17) from test stand pressure gauge outlet (38) to pump discharge fitting (18).Install 1/2 in. (12.7 mm) flexible hose (25) from test stand lube pressure (31) to test stand lubereturn (22).Install fuel input hose (37) from test stand fuel input connector (36) to pump discharge fitting (18).

Install fuel outlet hose (33) from test stand fuel outlet connector (34) to test stand fuel returnconnector (23).

Install leakage accumulator hose (40) to No. 1 accumulator can (41) from test stand leak testconnector (39).Connect 1/4 in. (6.35 mm) flexible hose (29) to check valve fitting (20) on fuel pump (11) and toauxiliary return connector (35).Install throttle lever position holding spring (1) from top of throttle shaft lever (3) to ring andadapter bracket (4). Spring (1) will hold throttle shaft lever (3) to full fuel position.

Remove governor spring pack housing pipe plug (2) from spring pack housing (5).

Install spring pack adjusting tool into spring pack housing (5).

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c. Fuel Pump Run-In

NOTEEnsure all other test stand valves are in the CLOSED position toprevent leakage. Seat all other test stand valves by opening onequarter turn and reclosing.

1. Place test stand (1), bypass valve (10), fuel pressure valve (9), and flow control valve (12) in openposition.

2. Open fuel pump (3) by turning fuel shutoff valve manual override knob (13) until seated.CAUTION

Check tachometer drive for clockwise rotation. If rotation is notclockwise, reverse rotation of drive coupling.

3. Apply lubricating oil to tachometer drive seal (2).

4. Place test stand power switch (8) in ON position.

5. Place test stand fuel heat switch (4) in ON position. Observe that fuel temperature gauge readsbetween 90o-100°F (32o- 38°C) for diesel fuel.

6. Place selector valve (11) in ROTAMETER position.7. Turn range crank (5) to HIGH range position.

NOTEPerform steps 8 and 9 only on Variable Speed (VS) governor.

8. Back high-adjusting screw (14), low-adjusting screw (15), and throttle lever (16) out ofVS governor (17) four turns.

9. Fasten VS governor throttle lever (17) in full fuel position.CAUTION

Pump must pick up fuel at 500 rpm without priming. If no fluidpickup is indicated at ROTAMETER, check fuel filter for improperinstallation, motor switch for correct rotation, open suction valveand hose, and that gear pump connections are tight.

10. Start test stand (1) by depressing start button (8) and run up to 500 rpm. To maintain 500 rpm,depress and release FAST (7) rotate SLOW (6) button.

NOTEl Check ROTAMETER for air in fuel flow. If air bubbles are

present, work pump throttle from fuel full-open to idle severaltimes to relieve entrapped air in pump.

l If air bubbling persists, it is an indication of an air leak in thesystem. Turn test stand off and check the line for looseconnections between tank and test stand pump, mating of gearpump housing, and full fuel supply tank (TM 9-4910-571-12).

l If pump is new or has been disassembled and reassembled, runpump at 500 rpm for 5 minutes to allow bearings and seals toseat and to purge air from system.

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d. Testing Pump Seals for Leaks

CAUTION

l Check tachometer drive for clockwise rotation. If rotation is notclockwise, reverse rotation of drive coupling.

l Do not leave fuel pressure valve closed more than five minutesbecause pump could overheat and be damaged.

NOTEAll steps must be completed before pump is considered calibrated.

1. With test stand (2) operating at 500 rpm, close fuel pressure valve (7).2. Place test stand fuel flow control valve (1) to OPEN position. If 25 in. vacuum is not obtained, check

all hose connections.3. Place bypass valve (8) in closed position.

4. Apply a small amount of GM grease over vent of weep hole (12). If grease is pulled into weephole (12) at 25 in. vacuum, fuel pump (10) oil seal is defective and fuel pump (10) must be replaced(para. 4-35).

5. Open fuel pressure valve (7).

e. Testing Governor Cutoff RPM

1. Open test stand fuel flow control valve (1) completely.2. Increase fuel pump (10) speed to 2,100 rpm by depressing and releasing FAST (5) or SLOW (6)

button.

3. Adjust test stand fuel flow control valve (1) to obtain 8 in. Mercury (HG) on vacuum gauge (4).NOTE

Once 8 in. HG vacuum setting is obtained, do not change setting.Readings will fluctuate during other tests. Just note the increasesor decreases as they occur.

4. Open the fuel flow control valve (1) and place the selector valve (9) in ROTAMETER position.5. Increase pump (10) speed until the fuel pressure drops. Stand tachometer (3) reading should be

2,130-2,150 rpm. Depress and release FAST (5) or SLOW (6) button to increase or decrease rpm.The VALVES governor automotive governor portion is set 100 rpm higher.

CAUTION

Test stand must be shut off to change shims in spring pack.NOTE

l Perform steps 6 and 7 only if spring pack shims are changed.l Each .001 in. (0.25 mm) shim thickness will change speed

approximately two rpm.

l Shims are available in 0.005, 0.010, and 0.020 in. (0.13, 0.25,and 0.51 mm) thicknesses.

6. If cutoff is too low, remove spring pack (11) and add shims. If cutoff is too high, remove shims(para. 5-14).

7. With fuel pump (10) at 500 rpm, move throttle lever (13) back and forth until ROTAMETER showsno air and recheck governor cutoff rpm, steps 1 through 6.

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f. Testing and Adjusting Throttle Leakage

1. Increase fuel pump (9) speed to 2,100 rpm with fuel pump throttle lever (13) and place selector valve (7)to ROTAMETER position to see if any air is in system.

NOTEAt 2,100 rpm fuel flow, ROTAMETER FLOAT should read 315 pphon the scale.

2. Set fuel flow control valve (8) for 315 pph reading.3. Place selector valve (7) to LEAKAGE TEST position and place count selector switch (6) to the 1,000

position.4. Pull out dumping lever (2) to retain fuel in No. 1 burette (3).

CAUTION

Do not hold throttle lever in idle position any longer than twominutes to complete test. Pump may overheat, since fuel flow isused to cool the pump.

5. Remove throttle spring (4) and manually position throttle lever (14) to idle position.

6. Depress pulse counter button (5) to fill No. 1 burette (3).7. Push dumping lever (2) inward.

NOTEl Ensure burette is cleared of fuel in order to prevent overflow at

this time.l A test cycle is one-half minute duration.

l For one half minute cycle, fuel delivery is 40-70 cc.

8. At the end of a cycle, read the amount of fuel in number one burette (3) on the scale.

9. If throttle leakage is not as specified, back rear throttle screw (12) out to decrease leakage and in toincrease leakage.

g. Testing and Adjusting Idle Speed

1. Place selector valve (7) to IDLE position and increase fuel pump (9) rpm to 500.

2. Pull fuel pump throttle lever (13) to idle position.

3. If fuel pressure is not 26 psi (179.27 kPa), adjust idle screw (10) in governor spring pack housing (11)using adjusting tool.

4. If pressure is low and the adjusting screw bottoms, stop the test stand, add shims to the spring endof the adjusting screw (para. 5-14), and retest cutoff rpm and throttle leakage, tasks e. and f.

NOTEEach time governor spring pack housing or adjusting tool isremoved, run pump until purged of air.

5. After proper adjustment is made, stop the test stand (1) and remove adjusting tool.6. Install 1/8 in. (3.17 mm) pipe plug (14) removed in steps 17 and 18, task b.

7. Purge the fuel pump (9) of air.

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h. Checking and Adjusting Throttle Lever Travel

1.

2.

3.

4.

5.

6.

7.

8.

NOTETravel template or indicator, level, and angle will be used to setpump throttle lever for travel adjustment. Ensure the combinationof the first and third or second and fourth holes on the templateare used. Any other combination will result in an inaccuratereading. Correct travel is 27-79o.

Place template (7) against throttle housing (8) so inside flats are even on top and bottom.CAUTION

DO NOT adjust rear throttle screw from valve set under throttlelinkage. The rear throttle screw has already been set to providethe proper deceleration time for the engine, and any changes atthis point will require recalibration of throttle linkage.

Move the throttle lever (6) to idle position.NOTE

The throttle lever may be repositioned on shaft as required to lineup the lever and template holes.

Line up template (7) idle hole and center of throttle lever (6) with straightedge.

Move the throttle lever (6) to full throttle position and align template (7) holes with hole in throttlelever (6).

NOTESteps 5 through 8 check throttle lever travel adjustment.

Place level and angle indicator against the bottom of throttle lever (6) and move throttle lever (6) toidle position. Note reading on scale of angle indicator.Move throttle lever (6) to full throttle position. Note reading on scale of angle indicator.

Add readings taken in steps 5 and 6. If throttle lever (6) travel is not 27-29o, adjust front throttlestep screw (9) to obtain correct ravel.After proper adjustment, the throttle lever (6) may be repositioned to accommodate throttle linkage.

i. Testing and Adjusting Pump Main Pressure

1. With test stand (2) vacuum set at 8 in. HG on vacuum gauge (5) and throttle wide open, adjustspeed to 2,100 rpm.

2. Place selector valve (4) to ROTAMETER position.

3. Set fuel flow to 3.15 pph with fuel flow control valve (1).

4. If fuel pressure reading on pressure gauge (3) is not 172-178 psi (1186-1227 kPa), adjust fuelpressure.

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j. Testing and Adjusting Fuel Pressure

NOTEThrottle shaft internal adjusting screw is covered by a throttleshaft ball in the end of throttle shaft.

CAUTION

Be careful not to damage bore of throttle shaft when drilling outball.

1. Center punch and drill ball (6) out of fuel pump throttle shaft (7) with 1/4 in. drill bit.2. Screw internal fuel adjusting screw located in fuel pump throttle shaft (7) inward to increase fuel

pressure and outward to decrease fuel pressure until it is set to 172-178 psi (1186-1227 kPa).3. After fuel pressure is adjusted, insert new throttle shaft ball (6) with throttle shaft installation tool.

k. Testing and Adjusting Governor Fuel Pressure

1. Adjust fuel pump (3) speed to 1,500 rpm.2. Place selector valve (4) on test stand (2) in ROTAMETER position.

3. Place fuel throttle lever (5) to wide-open position.4. Set fuel flow to 2.30 pph with the fuel control valve (1).5. If fuel pressure is not 100-106 psi (689-730 kPa), check governor cutoff rpm (task e).

l. Checking and Adjusting Governor Weight Pressure

1. Adjust fuel pump (3) speed to 1,000 rpm.2. Place throttle lever (5) to wide-open position.

3. Place selector valve (4) in ROTAMETER position.4. Set fuel flow to 150 pph with fuel flow control valve (1).

NOTEShims are available in 0.005 and 0.010 in. (0.13 and 0.25 mm)thickness. Do not change setting more than 0.020 in. (0.508 mm)from specification.

5. If fuel pressure is greater than 58 psi (399 kPa), decrease pressure by removing shims from behindweight plunger.

6. If fuel pressure is less than 50 psi (335 kPa), increase pressure by adding shims (para. 5-17).

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m. Testing and Adjusting Idle Speed (VS Governor Only)

NOTETo calibrate fuel pump equipped with Variable Speed (VS)governor, the preceding steps are followed. In addition, task c,steps 8 and 9 are to adjust VS governor only.

1. On test stand (2), place throttle lever (8) of fuel pump with VS governor (3) and VS governor lever (7)to full-fuel position.

2. Increase fuel pump (3) speed to 2,140 rpm.3. Loosen locknut (5), turn HI-IDLE (top) screw (4) in until fuel pressure starts to drop. Tighten

locknut (5).4. Decrease fuel pump (3) speed to 2,100 rpm, and gradually increase until pressure starts to drop.5. If fuel pump (3) speed is not 2,120-2,140 rpm, adjust VS governor HI-IDLE screw (4) until rpm is

2,120-2,140 rpm.

NOTEThe automotive governor cutoff must be set 100 rpm higher.

6. Decrease fuel pump (3) speed to 500 rpm.7. Place VS governor lever (7) and stand selector valve (1) to IDLE position.8. Adjust governor LO-IDLE screw (bottom) (6) to obtain 26 psi (179 kPa).

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n. Shutdown and Removal from Test Stand

1. Depress test stand stop button (11).2. Place test stand fuel heat switch (10) in OFF position.

3. Close test stand fuel pressure control valve (12) and fuel flow control valve (17).

4. Remove 1/4 in. (6.35 mm) flexible hose (13) from small fitting (9) on fuel pump (3) and auxiliaryreturn fitting (16) on test stand (2).

5. Remove leakage accumulator hose (15) from No. 1 accumulator can (14) and stand leak testconnector (17).

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6.7.

8.

9.

10.11.

12.

13.14.15.

16.17.

Remove fuel outlet hose (10) from test stand fuel input connector (11) and fuel return connector (5).Remove 1/2 in. (12.7 mm) flexible hose (8) from test stand lube pressure (9) and test stand lubereturn (6).Remove fuel pressure hose (14) from test stand pressure gauge outlet (13) and pump dischargefitting (2).Remove pump discharge fitting assembly (3) from pump fuel shutoff valve (4) and test stand fuelinput connector (12).Remove throttle lever spring (15) from fuel pump (7).Remove 1/4 in. (6.35 mm) manifold hose (17) from test stand manifold vacuum gauge (16) and1/4 in. (6.35 mm) adapter on inlet adapter assembly (18).

Remove 1/2 in. (12.7 mm) inner diameter flexible hose (22) from fuel pressure control valve (23) andadapter elbow on inlet adapter assembly (21).Remove pump inlet adapter assembly (20) from pump inlet port (19).Remove pump coupling insert (35) from test stand drive coupling (30).Loosen bar clamp (34) and slide fuel pump (7) and ring and adapter bracket (31) back from teststand drive coupling (30).Remove fuel pump (7) from ring and adapter bracket (31) by removing four screws (32) and washers (33).Remove nut (26), lockwasher (27), washer (28), screw (29), and throttle lever (25) from throttle levershaft (24).

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FOLLOW-ON TASKS: l Install throttle shaft cover (para. 5-16).l Install fuel pump shutoff valve (para. 4-36 or 4-37).l Install fuel pump on vehicle (para. 4-35).

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5-19. FUEL INJECTOR REPAIR

THIS TASK COVERS:a. Non-Top Stop Injector Disassemblyb. Top Stop Injector Disassemblyc. Inspection

d. Non-Top Stop Injector Assemblye. Top Stop Injector Assembly

INITIAL SETUP:


SPECIAL TOOLSCup retainer wrench (Appendix E, Item 162)Crowfoot injector wrench-(Appendix E, REFERENCES (TM)

Item 164) TM 9-2320-272-24PAdjusting wrench (Appendix E, Item 3)Locknut wrench (Appendix E, Item 165)Injector body wrench (Appendix E, Item 70)

EQUIPMENT CONDITIONFuel injectors removed (para. 4-32).

TOOLS GENERAL SAFETY INSTRUCTIONSl Keep fire extinguisher nearby when using

drycleaning solvent.

MATERIALS/PARTSInjector overhaul kit (Appendix D, Item 255)Diesel fuel (Appendix C, Item 42)Drycleaning solvent (Appendix C, Item 71)

General mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 144)Magnifying glass l Drycleaning solvent is flammable and toxic. Do

not use near an open flame.

a. Non-Top Stop Injector Disassembly

1. Remove injector link (1) from injector (8). Set injector link (1) aside to prevent damage.

WARNING


CAUTION

Improper cleaning methods and use of unauthorized cleaningsolvents can damage equipment.

2. Clean exterior of injector (8) with drycleaning solvent (para. 2-14).CAUTION

l Injector barrel and plunger are a matched pair (class fit). Do notinterchange.

l Do not touch internal parts unless hands are clean andmoistened with diesel fuel. Failure to do so may result indamage to internal parts.

3. Remove plunger (2) and spring (3) from injector (8). Store plunger (2) by standing on end.4. Remove small O-ring (4) and two large O-rings (5) from injector (8). Discard O-rings (4) and (5).

5. Remove screen retaining ring (6) and screen (7) from injector (8). Discard retaining ring (6) andscreen (7).

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5-19. FUEL INJECTOR REPAIR (Contd)

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6. Install injector body wrench in vise.7. Slide flat machined areas of injector (6) into body wrench.8. Loosen cup retainer (1) with cup retainer wrench.9. Remove injector (6) and body wrench from vise.

CAUTION

When handling injector, use care not to drop or lose parts.10. Set injector adapter (3) upright on flat surface and remove cup retainer (1) by lifting straight up.11. Remove injector cup (2) from injector (6). Discard injector cup (2).

CAUTION



12. Hold injector barrel (5) and adapter (3) together and set injector barrel (5) end upright on cleancloth. Lift adaptor (3) straight out of injector barrel (5) while holding injector barrel (5).

13. Lift injector barrel (5) up and tilt over hand until check ball (4) falls out.

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b. Top Stop Injector Disassembly

1.2.3.4.5.6.

7.8.9.

10.

11.

12.13.14.

WARNING


CAUTION

l When handling injector, use care not to drop or lose parts.l Improper cleaning methods and use of unauthorized cleaning

solvents can damage equipment.Clean exterior of injector (6) with drycleaning solvent (para. 2-14).Install injector body wrench in vise.Slide flat machined areas of injector (6) into injector body wrench.Loosen locknut (4) with locknut wrench.Loosen adjusting screw (3) with adjusting wrench.Remove adjusting screw (3), locknut (4), plunger (2), spring retainer (1), and plunger spring (7) frominjector (6).Loosen cup retainer (5) using cup retainer wrench.Remove injector (6) and body wrench from vise.Set injector adapter (9) upright on flat surface and remove cup retainer (5) by lifting straight up.Remove injector cup (8) from injector (6). Discard injector cup (8).

CAUTION



Hold injector barrel (11) and adapter (9) together and set injector barrel (11) end upright on cleancloth. Lift adapter (9) straight up out of injector barrel (11) while holding injector barrel (11).Lift injector barrel (11) up and tilt over hand until check ball (10) falls out. Discard check ball (10).Remove small O-ring (13) and two large O-rings (12) from injector (6). Discard O-rings (13) and (12).Remove screen retaining ring (14) and screen (15) from injector (6). Discard screen retaining ring (14)and screen (15).

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c. Inspection

1.

2.

3.

4.

NOTEl Bright spots or surface disruption at top of plunger-machined

area, on opposite side at bottom or midpoint, are normal resultsof rocker lever action.

l This task pertains to the non-top stop and top stop injectors.Inspect machined surfaces of plunger (1) for pitting, wear, cracks, and looseness. Narrow streaksrunning length of plunger (1) are normal. Plunger (1) should be one solid part. If plunger (1) ispitted or worn, or if cracks or looseness exist, replace plunger (1) and injector barrel (4).

Inspect injector barrel plunger bore (2) for scoring with strong magnifying glass. If scoring exists,replace injector barrel (4) and plunger (1).Inspect injector barrel (4) surface at each end for burrs or scratches. If burrs or scratches exist,replace injector barrel (4) and plunger (1).Inspect injector barrel check ball seat (3) for nicks or burrs. If nicks or burrs exists, replace injectorbarrel (4) and plunger (1).

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d. Non-Top Stop Injector Assembly

CAUTION



1. Place new check ball (6) in palm of hand and scoop up into injector barrel (4).2. Place injector barrel (4) flat on clean cloth so mating surface faces upward and align spiral pins (7)

with holes in adapter (5)

3. Place adapter (5) on injector barrel (4) and hold together. Set adapter (5) upright on clean cloth.4. Position new injector cup (9) on top of injector barrel (4) and screw cup retainer (8) onto adapter (5).

Finger tighten cup retainer (8), and back off 1/4 turn.

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5. Place injector cup retainer wrench over cup retainer (3).CAUTION



6.

7.8.9.

10.11.12.

13.14.

Apply clean diesel fuel to coat plunger (2) and insert plunger (2) into adapter (1).

Remove loading fixture stud (6) from loading fixture (4) and slide body wrench over injector (5) flats.Position cup retainer wrench on cup retainer (3).Install loading fixture stud (6) in loading fixture (4) and tighten 110 lb-in. (12 Nlm).Tighten cup retainer (3) 50 lb-ft (68 Nlm) with torque wrench and crowfoot wrench.Remove loading fixture stud (6) from loading fixture (4) and lift injector (5) out of loading fixture (4).Remove plunger (2) from adapter (1).

Apply clean diesel fuel to coat plunger (2).Insert plunger (2) into injector (5) barrel so plunger (2) remains 0.5 in. (12.7 mm) from edge ofadapter (1).

15. Press plunger (2) into cup retainer (3) with palm of hand.CAUTION

Do not allow plunger to fall out during step 16.

16.

17.

18.

19.20.21.

Turn cup retainer (3) and adapter (1) with one hand so cup retainer (3) faces upward. Plunger (2)should slide out immediately. If plunger (2) does not slide out immediately, the injector (5) is notaligned and must be reassembled as outlined in task b., steps 5 through 14.

Slide two new large O-rings (10) over end of injector (5) and into two upper grooves (15) on adapter.Slide new small O-ring (9) over end of injector (5) onto lowest groove (13) on adapter (1).

Place new inlet fuel screen (11) over adapter orifice (14) and install with new retainer ring (12).Place spring (8) on plunger (2) and slide plunger (2) into injector (5).Install injector link (7) in plunger (2).

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e. Top Stop Injector Assembly

1.2.3.4.5.6.

Place new check ball (3) in injector barrel (4).Place injector barrel (4) flat on clean lint-free cloth so mating surface faces upward.Place adapter (2) on injector barrel (4).Hold injector barrel (4) and adapter (2) together and set adapter (2) upright on clean lint-free cloth.Position new injector cup (6) on top of injector barrel (4).Screw cup retainer (5) onto adapter (2), finger tighten, and back off 1/4 turn.

CAUTION



7. Apply clean diesel fuel to coat plunger (1).8. Insert plunger (1) into adapter (2).9. Remove loading fixture stud (7) from loading fixture (8) and insert injector (9) into loading fixture (8).

10. Slide body wrench over flats on injector adapter (2).11. Position cup retainer wrench on cup retainer (5).12. Install loading fixture stud (7) in loading fixture (8) and tighten 75 lb-ft (8 Nlm).13. Tighten cup retainer (5) 50 lb-ft (68 Nlm) with torque wrench and crowfoot wrench.

CAUTION

l Lubricate parts only with clean diesel fuel before assembly. Donot use lubricating oil. Oil can crystallize under excessive heat,causing damage to injector components.


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14.15.16.17.18.

Remove injector (4) and body wrench from loading fixture.Remove plunger (2) from injector (4).Apply clean diesel fuel to coat plunger (2).Insert plunger (2) into injector (4) so plunger (2) remains 0.5 in. (12.7 mm) from edge of adapter (1).Press plunger (2) into cup retainer (3) with palm of hand.

CAUTION

19.

20.21.22.23.24.

Do not allow plunger to fall out. Damage to plunger may result.Turn cup retainer (3) and adapter (1) with one hand so cup retainer (3) faces upward. Plunger (2)should slide out immediately. If plunger (2) does not slide out immediately, the injector (4) is notaligned and must be reassembled as outlined in steps 1 through 18.Install body wrench in vise.Slide injector (4) into body wrench.Place spring (9) and spring retainer (5) in injector (4).Slide plunger (2) into injector (4).

25.26.

Thread locknut (8) and adjusting screw (7) into injector (4) with locknut wrench and top-stopadjusting wrench (6) until locknut (8) contacts adapter (10). Tighten locknut (8) 55 lb-ft(75 Nlm).Remove injector (4) from body wrench.Slide two new large O-rings (15) over end of injector (4) and into two upper grooves (11) and (12) ofadapter (10).

27. Slide new small O-ring (14) over end of injector (4) into lowest groove (13) on adapter (10).28. Place new inlet fuel screen (17) over adapter orifice (18) and install with new retainer ring (16).

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FOLLOW-ON TASK: Install fuel injectors (para. 4-32).

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5-20. INJECTOR LEAK TEST

THIS TASK COVERS:a. Setting Up Injector Leakage Detector b. Testing Injector Plunger and Seat

INITIAL SETUP:


SPECIAL TOOLS EQUIPMENT CONDITIONInjector leakage detector (Appendix E, Item 68) Fuel injectors removed (para. 4-32).

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Feeler gauge

a . Setting Up Injector Leakage Detector

1.

2.

3.4.5.

6.7.

Set pressure regulator on leakage tester at 60 psi (414 kPa). Read pressure setting on pressureregulator gauge (1).Operate retraction lever (3) on leakage tester three times, and reset pressure regulator gauge (1) at60 psi (414 kPa).

NOTEAir pressure must be held at 60 psi (414 kPa) during all tests.

Place leakage tester retraction lever (3) in position A.Position load cell (2) on leakage tester.Adjust knurled knob (4) on load cell (2) until load cell (2) reads 200 psi (1,379 kPa).

NOTEDo not adjust locknut unless load cell is in use.

Place feeler gauge between knurled knob (4) and locknut (5) and adjust locknut (5).

Remove load cell (2) from leakage tester.

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5-20. INJECTOR LEAK TEST (Contd)

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b. Testing Injector Plunger and Seat

1. Remove plunger (2) and spring (3) from injector (4).2. Install injector link (1) in plunger (2) and place in injector (4).

3. Remove screen retaining ring (6) and inlet fuel screen (7) from injector (4).4. Align injector delivery orifice (5) with burnishing tool hole (11) on burnishing tool adapter (10).

5. Insert locating screw (8) in locating screw hole (9) on burnishing tool adapter (10) and tighten.

NOTESupport plate may be tilted.

6.7.8.

9.

10.

11.

12.13.14.15.

Position injector (4) on support plate (14) and install in leakage tester.Place feeler gauge between knurled knob (17) and locknut (18). Do not adjust locknut (18).Install transfer line (20) and tighten in injector adapter (13) drain port.

Tighten T-handle clamp (15).Shift retraction lever (16) from position A to position B. Ensure plunger (2) retracts.

Rotate plunger (2) in clockwise direction a little at a time while reading air flow meter (12).Stop rotating plunger (2) when highest reading is obtained.If air flow meter (12) reading is over 4.5, overhaul injector (4) (para. 5-19).Shift retraction lever (16) from position B to position A.Loosen T-handle clamp (15). This will apply 200 lbs (91 kg) load to plunger (2).While observing checker (21), see if any bubbles appear during the first ten seconds of testing.No bubbles should appear.

16.

17.18.19.

20.

21.

22.

23.

24.

If a bubble does appear, observe the time it takes for the next one to appear. No more thanone bubble can appear every five seconds. If bubbling is too high, overhaul injector (4) (para. 5-19).Remove transfer line (20) from injector adapter (13) drain port.Release air pressure from pressure regulator (19).Remove injector adapter (13) from leakage tester.

Remove locating screw (8) and transfer line (20) from burnishing tool adapter (10).

Remove injector (4) from burnishing tool adapter (10).

Place inlet fuel screen (7) over injector orifice (5), and install with retainer ring (6).

Remove plunger (2) and injector link (1) from injector (4).

Place plunger (2) and spring (3) in injector (4).

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5-21. INJECTOR SPRAY PATTERN TEST

THIS TASK COVERS:

a. Setting Up Spray Pattern Tester b. Testing Spray Pattern

INITIAL SETUP:


SPECIAL TOOLSFuel injection tester (Appendix E, Item 49)Spray angle tester (Appendix E, Item 138)


EQUIPMENT CONDITIONFuel injectors removed (para. 4-32).

GENERAL SAFETY INSTRUCTIONSTOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)

Whenever fuel is forced from injector spray holes,keep hands away from spray stream.

a. Setting Up Spray Pattern Tester

NOTEAny source of 22 psi (152 kPa) constant fuel pressure will operatespray pattern tester.

1. Locate spray pattern tester near or on injector test stand.2. Attach inlet hose (2) to adapter (8) from injector test stand.3. Attach drain hose (4) to adapter base (5) and place loose end in test stand drain area.4. Remove plunger (10) and spring (11) from injector (12) and store in safe place.5. Remove screen retaining ring (15) and inlet fuel screen (14) from injector test stand.

6. Place injector (12) in adapter (8).

7. Install knurled plug (6) in adapter (8) drain opening.

8. Place injector (12) in spray pattern tester and tighten inlet hose connector (3).9. Install injector (12) in spray patter tester holddown bracket (9) with knurled knob (1).

10. Install target ring (7) marked 8-.007 x 17o on spray pattern tester.

b. Testing Spray Pattern

WARNING

Keep hands away from spray stream when fuel is forced from injectorspray holes. Failure to do this may result in injury to personnel.

1. Apply 22 psi (152 kPa) pressure to injector test stand.NOTE

Each spray stream must hit a window in the target ring.

2. Shift target ring (7) so one spray stream hits on No. 1 or index window. If spray stream is off 2o ofwindow, replace cup (para. 5-19).

3. Loosen knurled knob (1) on holddown bracket (9).

4. Remove injector (12) from spray pattern tester.5. Remove knurled plug (6) and injector (12) from adapter (8).

6. Install spring (11) and plunger (10) in injector (12).7. Install inlet fuel screen (14) over injector orifice (13) with screen retaining ring (15).

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5-21. INJECTOR SPRAY PATTERN TEST (Contd)


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5-22. INJECTOR TEST STAND CALIBRATION

THIS TASK COVERS:

a. Setting Up Injection Tester b. Test Stand Calibration

INITIAL SETUP:

APPLICABLE MODELS TOOLSM939/A1 General mechanic’s tool kit (Appendix E, Item 1)

SPECIAL TOOLS REFERENCES (TM)Fuel injection tester (Appendix E, Item 49) TM 9-2320-272-24P

a. Setting Up Injection Tester

1. Rotate counter wheel (2) on injection tester until wheel marks and pointer are aligned.2. Open hydraulic valve (3).

CAUTION

3.4.

5.6.

Never operate test stand with load cell in position.

Position load cell tester on injection tester and secure by opening air valve (4).Adjust air regulator (5) by turning knurled knob (7) until load cell tester registers within codedrange markings. Record air gauge (1) pressure reading.Lock air regulator (5) in place with locknut (6).Place air valve (4) to center position and remove load cell tester from injection tester.

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5-22. INJECTOR TEST STAND CALIBRATION (Contd)

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7. When cylinder (11) is down, hydraulic fluid should show in sight bulb. Open air valve (13) whencylinder (11) is at the top of its travel; no air should show in sight glass (14). If air is indicated,tighten all line connections.

NOTEThe master injector is precalibrated and must never be tamperedwith.

8. Place adapter (20) on master injector (17). Ensure wheel marks and pointer are aligned (step 1).NOTE

Ensure injector seat contains 0.20 in. (0.51 mm) restrictor orifice.9. Position test stand link (15) over injector link (9) and place master injector (10) in injector seat (18).

10. Tip back until test stand link (15) is below test stand push rod (8) and not rubbing.

11. Open air valve (13) to clamp master injector (10) in place. Ensure test stand link (15) is aligned.

12. Close hydraulic valve (12) to lock master injector (10) in place.

13. Connect test stand fuel drain connector (19) to adapter (20).14. Connect test stand fuel inlet connector (16) to adapter (20).

CAUTION

If temperature exceeds 135°F (57°C), drain and replace with newtest oil.

15. Place injector test stand motor switch (6) in START position. Ensure temperature gauge (7) reads90°-95°F (32-35°C).

16. Shift the silver colored counter (1) wheels (3) to the right, rotate counter (1) to indicate 1,020strokes and release.

17. Clear counter (1) by rotating thumbscrew (4) one complete revolution. Ensure all white-coloredcounter wheels (2) read zero.

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b. Test Stand Calibration

1. Adjust regulator knob (5) on injector test stand by turning until pressure gauge (1) reads 120 psi(827 kPa). Ensure pressure is maintained at 120 psi (827 kPa) during calibration.

2. Press red flow start switch (3) in and out until counter (4) reads 1,020 count strokes.3. Look directly into vial (2) and observe reading.

NOTEReading of 132 counterclockwise at 120 psi (827 kPa) indicatestest stand is in calibration. If reading is more than 132 cc, the teststand is not set up properly. Repeat setup steps. If reading isbelow 132 cc, continue.

4. Reset counter (4) on injector test stand to zero (task a., steps 16 and 17).5. Set counter (4) up seven strokes for each cc less than 132 cc.6. Dump fuel from vial (2).

NOTEIf counter is set beyond 1,050 strokes to obtain 132 cc, the teststand is not set up properly. Repeat setup steps. If counter reads1,050 or below, the test stand is in calibration.

7. Press red flow start switch (3) in and out until counter (4) sets strokes to obtain 132 cc.8. Place motor switch (6) in STOP position.9. Remove test stand fuel drain connector (14) from adapter (15).

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10. Open hydraulic valve (9).

11. Close air valve (10).12. Remove master injector (8) from injector seat (13).

13. Slide test stand link (11) off injector plunger link (7).14. Remove test stand fuel inlet connector (12) from adapter (15).15. Remove adapter (15) from master injector (8).

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5-23. INJECTOR FLOW TEST

THIS TASK COVERS:a. Setting Up Test Standb. Testing Check Ball Seating

c. Adjusting and Measuring Fuel Delivery

INlTIAL SETUP:

APPLICABLE MODELSM939/Al

SPECIAL TOOLSInjection tester (Appendix E, Item 49)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Burnishing tool adapterAdjusting tool adapter

MATERIALS/PARTSGasket (Appendix D, Item 240)Diesel fuel (Appendix C, Item 42)


EQUIPMENT CONDITION• Fuel injector removed (para. 4-32).• Injector test stand calibrated (para. 5-22).

SPECIAL ENVIRONMENTAL CONDITIONSWork area clean and free from blowing dirt and dust.

a. Setting Up Test Stand

1. Remove screen retainer ring (5) and inlet fuel screen (4) from injector (3).2. Remove plunger (1) and spring (2) from injector (3) and separate plunger (1) from spring (2).

3. Place plunger (1) in injector (3) without spring (2).4. Apply diesel fuel to lubricate inside of burnishing tool adapter.

CAUTION

Injector inlet port and burnishing tool adapter inlet hole must bealigned to prevent damage to the burnishing tool points wheninstalled later.

5. Position injector (3) in burnishing tool adapter so injector (3) inlet port and burnishing adapter inletholes align. Tighten locating screw (12) on burnishing tool adapter to install injector (3).

6. Connect test stand inlet pressure line adapter (11) to burnishing tool adapter.

b. Testing Check Ball Seating

NOTEHold injector in hand; do not place in test stand holding device,

1. Hold plunger (1) down in injector (3).2. Place motor switch (7) on injection tester in START position. Ensure temperature gauge (9) reads

90-95°F (32-35°C).CAUTION

If temperature exceeds 135°F (57°C), drain and replace with newtest oil.

3. Adjust regulator knob (9) by turning until pressure gauge (6) reads 150 psi (1,034 kPa).4. Check burnishing tool adapter installation hole (10) for leaks. A slight seepage is not harmful. If

leakage is found, replace check ball (para. 5-19).

5. Place motor switch (7) in STOP position.

6. Disconnect test stand inlet pressure line adapter (11) from burnishing tool adapter.

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5-23. INJECTOR FLOW TEST (Contd)

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c. Adjusting and Measuring Fuel Delivery

1.2.3.4.

5.

6.7.

8.

9.10.

11.12.

Remove plunger (11) from injector (9).

Slide spring (12) on plunger (11) and place in injector (9).Place retainer plate (14) on burnishing tool adapter and secure with pins (13).Place test stand link (1) in burnishing tool adapter. Test stand link (1) should be 6.5 in. (17 cm)long.

Place injector (9) in injector test stand (7) so injector (9) is in injector seat (8). Tip injector (9) backuntil test stand link (1) is below test stand push rod (16) and is not rubbing.Install burnishing tool (2) in test stand inlet pressure line adapter (9).Retract burnishing tool needle (4) by pulling small knob (3) out.

NOTEWith needle retracted, burnishing tool may be left in adapterduring all test operations.

Connect test stand inlet pressure line adapter (6) to burnishing tool adapter inlet hole by screwingin large knob (5).

Install drain connector (10) in burnishing tool adapter.Clamp injector (9) in place by opening air valve (18). Ensure test stand link (1) is aligned.

Lock injector (9) in place by closing hydraulic valve (17).Place motor switch (15) in START position. Ensure temperature reads 90°-95° F (32°-35°C).

CAUTION

If temperature exceeds 135 °F (57°C), drain and replace with newtest oil.

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13. Adjust injector test stand regulator knob (6) by turning until pressure gauge (1) reads 120 psi(827 kPa).

14. Press flow start switch (4) in until counter (5) reads the same as master injector counter strokes.

15. Observe vial (2) reading, If reading is higher than 122 cc at 120 psi (827 kPa), perform steps 17through 19 to install new orifice plug (16). If reading is lower than 121 cc at 120 psi (827 kPa),perform steps 20 through 24 to set fuel flow.

16. Remove test stand inlet pressure line adapter (11) and burnishing tool from burnishing tooladapter (13) by turning large knob (9) out until assembly is free.

17. Remove orifice plug (16) and gasket (15) from injector (10). Discard gasket (15).NOTE

New orifice plug size .018-.019 in. (0.48-0.49 mm) is small enoughso burnishing will increase fuel efficiency.

18. Install new gasket (15) and orifice plug (16) in injector orifice (14) and tighten orifice plug (16)8-10 lb-in. (0.9-1.1N• m).

19. Install test stand inlet pressure line adapter (11) and burnishing tool on burnishing tool adapter (13)by screwing large knob (9) into burnishing tool adapter (13) inlet hole until tight.

CAUTION

20.21.22.23.

24.

25.

26.

27.

Place injector test stand motor switch (3) in STOP position.

Remove drain connector (12) from burnishing tool adapter (13).

Screw out large knob (9) on burnishing tool and remove test stand inlet pressure line adapter (11) fromburnishing tool adapter (13).

28. Remove burnishing tool from burnishing tool adapter (13). Store burnishing tool in clean place.

When seating burnishing tool, use care not to push small knob intoo hard or overtighten indicator knob. When slight contact ismade, stop. Damage can be caused to injector. Test stand must berunning while burnishing.

Turn burnishing tool indicator knob (8) until spaced 3/8 in. (9.5 mm) from large knob (9).Slowly push small burnishing tool knob (7) in until slight contact is made with injector (10).Turn small burnishing tool knob (7) counterclockwise to lock large knob (9) and indicator knob (8).Slowly turn indicator knob (8) in until slightly seated in injector (10). Index indicator knob (8) withmark on large knob (9).

Advance indicator knob (8) one mark, and back off until spaced 3/8 in. (9.5 mm).

NOTEPerform steps 12 through 15 and recheck fuel delivery. If deliveryis lower than 121-122 cc, repeat steps 20 through 24. If reading ishigher, install new orifice plug (steps 17 through 19), and recheckfuel delivery.

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29. Open hydraulic valve (2) on injector test stand.30. Close air valve (3) on injector test stand.

31. Remove injector (1) from injector test stand.32. Slide test stand link (7) out of burnishing tool adapter.33. Remove two pins (4) and retainer plate (5) from burnishing tool adapter.34. Remove burnishing tool adapter from injector (6).

35. Remove plunger (8) and spring (9) from injector (1).36. Install screen (10) in injector orifice (12) with screen retainer (11).

37. Place spring (9) in plunger (8) and slide in injector (1).NOTE

Store injectors in a clean place.

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FOLLOW-ON TASK: Install fuel injector (para. 4-32).

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TM 9-2320-272-24-4

Section II. ENGINE (M939A2) MAINTENANCE

5-24. ENGINE (M939A2) MAINTENANCE INDEX

PARA.NO. TITLE PAGE

NO.

5-25. Cylinder Head Repair 5-158

5-26. Piston and Connecting Rod Maintenance 5-166

5-27. Camshaft and Gear Maintenance 5-174

5-28. Cylinder Liners and Block Maintenance 5-184

5-29. Crankshaft and Gear Maintenance 5-196

5-30. Rocker Levers and Push Rods Maintenance 5-206

5-31. Mounting Fuel Injection Pump to Test Stand 5-210

5-32. Fuel Injection Pump Pretest 5-214

5-33. Manifold Pressure Compensator Maintenance 5-224

5-34. R.Q.V. Governor Cover Maintenance 5-228

5-35. R.Q.V. Governor Housing Maintenance 5-232

5-36. Fuel Injection Pump Maintenance 5-240

5-37. Fuel Injection Pump Calibration 5-262

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5-25. CYLINDER HEAD REPAIR

THIS TASK COVERS:a. Disassemblyb. Cleaningc. Inspection

d. Repaire. Assembly

INITIAL SETUP:

APPLICABLE MODELSM939A2

TOOLS

General mechanic’s tool kit (Appendix E, Item 1)Spring compressor (Appendix E, Item 135)Gauge block (Appendix E, Item 52)Spring tester (Appendix E, Item 131))Vernier caliper (Appendix E, Item 159)Dial indicator (Appendix E, Item 36)Feeler gaugeValve refacing machine

MATERIALS/PARTSTwenty-four collets (Appendix D, Item 253)Twelve seals (Appendix D, Item 613)Eight expansion plugs (Appendix D, Item 105)Expansion plug (Appendix D, Item 106)Two expansion plugs (Appendix D, Item 107)Antiseize tape (Appendix C, Item 72)Lapping compound (Appendix C, Item 37)Lubricating oil (Appendix C, Item 50)Pigment (Appendix C, Item 54)Sealing compound (Appendix C, Item 64)

REFERENCES (TM)TM 9-247TM 9-2320-272-24P

EQUIPMENT CONDITIONCylinder head removed (para. 4-41).

GENERAL SAFETY INSTRUCTIONSEyeshields must be worn when removing valves.

WARNING

Valve springs are under compression. Eyeshields must be worn whenremoving valves. Failure to do so may cause injury to personnel.

CAUTION

To remove intake and exhaust valves, position cylinder head onexhaust port face. Use wooden or protective surface work bench toprevent damage to cylinder head.

NOTE• Mark location and position of valves for installation.• All intake and exhaust valves are removed the same.

1. Using spring compressor, compress valve spring (3) and remove two collets (1) from valve (10) andcylinder head (9). Discard collets (1).

2. Release spring compressor and remove two spring retainers (2), valve spring (3), seal (4), andvalve (10) from cylinder head (9). Discard seal (4).

3. Remove five expansion plugs (5) from top face of cylinder head (9). Discard expansion plugs (5).4. Remove expansion plug (6) from rear face of cylinder head (9). Discard expansion plug (6).

5. Remove two expansion plugs (8) from front and rear faces of cylinder head (9). Discard expansionplugs (8).

6. Remove plug (7) from rear face of cylinder head (9).

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b. Cleaning

Clean all cylinder head components (TM 9-247).

c. Inspection

1. Inspect cylinder head (1) for cracks, pits, and scratches.a. If pitted or scratched, remove with crocus cloth.

b. If cracked, excessively pitted or scratched, replace cylinder head (1).2. Inspect cylinder head (1) for warping.

a. Using straight edge and feeler gauge, inspect gasket surface of cylinder head (1) from front torear. Warping should not exceed 0.008 in. (0.20 mm).

b. Inspect gasket surface of cylinder head (1) from side to side. Warping should not exceed 0.003 in.(0.076 mm).

c. Using 2-in. (51-mm) straight edge and feeler gauge, inspect for warping across valve ports (2) andcoolant passages (5). Warping should not exceed 0.001 in. (0.025 mm).

CAUTION

Machining of cylinder head surface is not to exceed 0.040 in.(1.02 mm) or damage to equipment will result.

d. Replace or resurface cylinder head (1) if warping exceeds limits. Notify your supervisor.NOTE

Perform steps 3 and 4 if cylinder head was resurfaced.3. Install valves (3) in their respective valve ports (2).

4. Using gauge block, measure depth of valves (3). Mark valve seat(s) (6) for resurfacing if depth is lessthan 0.043 in. (1.09 mm).

5. Remove valves (3) from cylinder head (1).6. Inspect valve springs (4) for distortion, cracks, and collapsed coils. Refer to table 5-9, Cylinder Head

Wear Limits, for measurements. Replace valve springs (4) if damaged or worn.7. Using spring tester, compress valve springs (4) to 2 in. (51 mm). Load measured should be

101.2-115 lb (45.9-52.2 kg). Replace valve spring(s) (4) if not within limits.8. Inspect valve spring retainers (8) for wear and distortion. Replace valve spring retainer(s) (8) if

worn or distorted.

Table 5-9. Cylinder Head Wear Limits.

ITEM NO.

3

14

15

4

ITEM/POINT OF MEASUREMENT

Intake and exhaust valvesRim thicknessValve stem diameter

Exhaust valve guideValve guide lengthValve guide bore, inner

Intake valve guideValve guide lengthValve guide bore, inner

Valve springsFree length

WEAR LIMITS/TOLERANCESINCHES MILLIMETERS

0.060 1.520.373 9.47

0.896 22.760.376 9.55

0.893 22.680.376 9.55

2.585 65.66

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9.

10.

11.

12.13.

14.

15.

Inspect valve seats (6) for wear, burrs, pits, and cracks. Replace cylinder head (1) if worn, pitted,cracked, or burred. Mark valve seat (6) for resurfacing.

Inspect exhaust (14) and intake (15) valve guides for chips, cracks, burrs, breaks, and wear. Replacecylinder head (1) if chipped, cracked, burred, broken, or worn.

Measure valve guide length (12) and inside diameter of valve guide bore (13). Refer to table 5-9,Cylinder Head Wear Limits, for measurements. Replace cylinder head (1) if not within limits.Inspect valves (3) for cracks, bends, and wear. Replace valve(s) (3) if cracked, bent, or worn.Measure outside diameter of valve stem (9). Refer to table 5-9, Cylinder Head Wear Limits, formeasurements. Replace valve(s) (3) if not within limits.Measure rim (10) thickness of valves (3). Refer to table 5-9, Cylinder Head Wear Limits, formeasurement. Replace valve(s) (3) if not within limits.Inspect collet grooves (11) for wear.

a. Install new collets (7) in collet grooves (11).b. If collets (7) fit loosely, replace valve(s) (3).

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1. Apply light coat of lapping compound to valve (2) and lap valve (2) to valve seat insert (1).2. Clean lapping compound from valve (2) and valve seat insert (1).3. Measure width of valve seat insert (1). Limits are 0.060-0.080 in. (1.52-2.03 mm). If beyond limits,

replace cylinder head (4).4. Check contact surface between valve (2) and valve seat insert (1) as follows:

a. Apply light coat of pigment to valve face (3).b. Lower valve (2) into valve guide (5) and let valve (2) drop against valve seat insert (1).

NOTEDo not rotate valve when pushing valve against valve seat insert.

c. Push up on valve stem (6) until valve face (3) is about 1 in. (25.4 cm) above valve seat insert (1).

d. While releasing valve stem (6), apply pressure to valve (2) until valve face (3) makes contact withvalve seat insert (1). Repeat several times to get good imprint on pigment.

NOTEDo not smear pigment from valve.

e. Remove valve (2).f. Imprint on pigment should have an even contact surface all around center of valve face (3). If

pigment imprint is uneven, mark valve (2) and valve seat insert (1) for grinding.

NOTERepeat step 4 for all valves to check contact surface between valveand valve seat insert.

5. Grind valve (2) and valve seat insert (1) if valve (2) is new or has an uneven contact surface.a. Use a 30° grinding wheel on valve seat insert (1) for intake port (7).b. Use a 45° grinding wheel on valve seat insert (1) for exhaust port (8).

NOTEIf contact surface is at bottom of valve face, valve seat insert willrequire more grinding with 15° wheel.

c. To center contact surface on valve face (3), grind area (11) of valve seat insert (1) with a 60°wheel, and area (12) of valve seat insert (1) with a 15° wheel.

d. Using valve refacing machine, grind face of intake valve (2) to a 30° angle or a 45° angle forexhaust valve.

6. If valve stem tip (10) is not flat, dress tip for flatness on grinding wheel.7. Measure valve (2) depth from bottom of cylinder head (4) to surface when valve (2) is seated against

valve seat insert (1).a. Position gauge block flat on surface of cylinder head (4) with plunger extended to cylinder head (4)

surface. Adjust dial indicator to zero.

b. Position gauge block flat on surface of cylinder head (4) with plunger extended to valve (2).

c. Valve (2) depth must measure 0.035-0.056 in. (0.89-1.42 mm) below bottom surface of cylinderhead (4).

d. If measurement is not within limits, use new valve (2) and repeat steps a through c.

e. If measure is beyond limit, replace cylinder head (4).8. Using pigment, check contact surface (9) between face of valve (2) and valve seat insert (1) (step 4d.).

9. Clean cylinder head (4) and valves (2) after valves (2) and valve seat inserts (1) have been ground(para. 2-14).

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1.2.3.4.

Install plug (8) on rear face of cylinder head (10).Install two new expansion plugs (9) on front and rear faces of cylinder head (10).Install new expansion plug (7) on rear face of cylinder head (10).Install five new expansion plugs (6) on top face of cylinder head (10).

CAUTION

Position cylinder head on exhaust port face to install intake andexhaust valves. Use wooden or protective surface work bench toprevent damage to cylinder head. Bench must be clean.

NOTEEnsure intake and exhaust valves are installed in originallocations as previously noted.

5.

6.7.

8.

Dip valve (11) stems in clean engine oil and install in valve guides (5) from face side of cylinderhead (10).Carefully position cylinder head (10) face down on bench.Install twelve new seals (4), valve springs (3), and spring retainers (2) on valves (11).

Using spring compressor, compress valve springs (3) until collet grooves (12) on valves (11) areexposed.

NOTEEnsure all valves are locked by collets.

9. Install twenty-four new collets (1) in collet grooves (12) and slowly release spring compressor.

NOTE• Wrap male pipe threads with antiseize tape before installation.

• Apply sealing compound to mating surfaces of expansion plugsbefore installation.

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FOLLOW-ON TASK: Install cylinder head (para. 4-41).

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5-26. PISTON AND CONNECTING ROD MAINTENANCE

THIS TASK COVERS:a. Removalb. Disassemblyc. Cleaning and Inspection

d. Assemblye. Installation

INITIAL SETUP:


SPECIAL TOOLSEngine barring tool (Appendix E, Item 43)Ring compressor (Appendix E, Item 32)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Keystone gauge (Appendix E, Item 54)Inside micrometer (Appendix E, Item 82)Outside micrometer (Appendix E, Item 80)Vernier calipers (Appendix E, Item 159)Torque wrench (Appendix E, Item 144)Depth gauge (Appendix E, Item 81)Feeler gaugeSoft-headed hammer

MATERIALS/PARTSPiston rings (Appendix D, Item 518)Two retaining rings (Appendix D, Item 539)Connecting rod bearing (Appendix D, Item 40)Lubricating oil (Appendix C, Item 50)Plastigage (Appendix C, Item 55)


EQUIPMENT CONDITlON• Cylinder head removed (para. 4-41).• Oil pan and suction tube removed (para. 4-47).

NOTEAll piston assemblies are replaced the same way. This procedurecovers replacement of one piston assembly.

a. Removal

1. Using engine barring tool, rotate crankshaft (6) to lower pistons (1) enough to remove all carbonfrom upper inside wall of each cylinder (3).

2. Remove two nuts (8) from screws (5) and connecting rod cap (7).

3. Using soft-headed hammer, tap screws (5) and remove connecting rod cap (7) from crankshaft (6).

CAUTION

Use a tape-protected tool to push piston from cylinder block.Failure to do so may cause damage to cylinder liners.

NOTEAssistant will help with step 4.

4. Using tape-protected tool, push connecting rod (2) and piston (1) from engine block (4).

b. Disassembly

CAUTION

Pistons, connecting rods, and connecting rod caps must be kept togetheras an assembly. Missing parts may cause damage to equipment.

1. Remove two retaining rings (12) from bore of piston (1). Discard retaining rings (12).

2. Remove piston pin (13) and connecting rod (2) from piston (1).

3. Remove ring (9), compression ring (10), and oil ring (11) from piston (1). Discard rings (9), (10),and (11).

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4. Remove two screws (5) from connecting rod (2).5. Remove upper half bearing shell (14) from connecting rod (2). Discard upper half bearing shell (14).6. Remove lower half bearing shell (15) from connecting rod cap (7). Discard lower half bearing shell (15).

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c. Cleaning and Inspection

1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Replace all parts failing inspection.

NOTEMeasurements to check piston skirt outside diameters are takenat right angle to piston pin bore.

4.

5.

Measure outside diameter of piston skirt (3) at several places. If diameter is less than 4.479 in.(113.8 mm), replace piston (4).Check piston ring groove (5) for wear.

6.

a. Insert keystone gauge into ring groove (5).b. If shoulders of keystone gauge touch either end of ring groove (5), replace piston (4).Check compression ring (6) and oil ring (7) grooves for wear.a. Insert new compression ring (1) into compression ring groove (6).

b. Try to insert 0.006 in. (0.152 mm) feeler gauge between compression ring (1) and compressionring groove (6).

c. If feeler gauge enters compression ring groove (6) without force, replace piston (4).d. Repeat steps a through c using new oil ring (2) and 0.005 in. (0.127 mm) feeler gauge to check oil

ring groove (7) for wear.7.

8.

9.

10.11.

12.

13.

14.15.

Measure inside diameter of piston pin bore (9). If inside diameter exceeds 1.773 in. (45.03 mm),replace piston (4).Measure outside diameter of piston pin (8). If outside diameter exceeds 1.771 in. (44.98 mm),replace piston pin (8).

Inspect I-beam section (15) of connecting rod (11) for nicks, dents, and gouges. If nicked, dented, orgouged, replace connecting rod (11).Install two connecting rod screws (12) in connecting rod (11).Install connecting rod cap (14) on connecting rod (11) with two nuts (13). Tighten nuts (13) to73 lb-ft (99 N•m).

Check crankshaft journal bore (10) of connecting rod (11) for wear:a. Measure inside diameter of crankshaft journal bore (10) at several points 30° from each other.

b. If inside diameter measurement exceeds 2.9926 in. (76.012 mm), replace connecting rod (11).Measure inside diameter of piston pin bore (16). If inside diameter exceeds 1.773 in. (45.03 mm),replace connecting rod (11).Remove two nuts (13) and connecting rod cap (14) from connecting rod (11).Check connecting rod journals (18) on crankshaft (17) for wear.

a. Measure outside diameter of six connecting rod journals (18) at A-A and B-B. If differenceexceeds 0.0005 in. (0.013), replace crankshaft (17) (para. 5-29).

b. Measure outside diameter of six connecting rod journals (18) at C-C and D-D. If differenceexceeds 0.002 in. (0.05 mm), replace crankshaft (17) (para. 5-29).

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d. Assembly

1.

• Ensure numbers on pistons, connecting rods, and connecting rodcaps match numbers on the mating cylinders.

• Perform step 1 if assembling with new connecting rod.

Install two connecting rod screws (8) on connecting rod (2). Ensure heads of screws (8) are on flat ofconnecting rod (2).

2.3.

4.

5.6.

Install retaining ring (13) in pin groove of piston (1).Position connecting rod (2) in piston (1). Ensure connecting rod (2) matches FRONT mark onpiston (1).Apply clean engine oil to lubricate piston pin (7) and piston pin bore (12).Install piston pin (7) through piston (1) and connecting rod (2).Install retaining ring (6) in pin groove of piston (1).

NOTE

7.8.

Piston rings must be installed on piston with the word TOP orsupplier’s mark facing upward.

Install new oil ring (5) in oil ring groove (14).Using piston ring expander, install new compression ring (4) and new ring (3) on piston (1).

NOTEAlign bearing shell tabs with connecting rod and connecting rodcap slots when installing.

9. Install new upper half bearing shell (9) in connecting rod (2).

10. Install new lower half bearing shell (10) in connecting rod cap (11).

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e. Installation

1. Apply clean engine oil to lubricate piston (3) and cylinder bore (5).NOTE

Ensure piston rings are staggered properly so they are not in linewith each other or piston pin.

2. Lubricate ring compressor and install over piston rings (4) and piston (3).3. Using engine barring tool, rotate crankshaft (91 until connecting rod journal (11) is at bottom

dead center.CAUTION

• Ensure piston assembly number matches that of matingcylinder. Failure to do so will cause poor engine performance.

• Ring compressor must be held firmly against engine block toprevent compressor from slipping and causing piston ringbreakage when pushing piston into cylinder liner.

• Do not force piston assembly into liner. If piston does not installfreely in liner, remove and check for broken rings.

NOTEEnsure piston assemblies are installed with FRONT mark facingfront of engine.

4. Insert connecting rod (7) in cylinder bore (5) and hold ring compressor tight and firmly seatedagainst engine block (6).

5. Using rubber or wooden mallet handle, push piston (3) from ring compressor and into cylinderbore (5) until upper half bearing (8) seats against connecting rod journal (11).

6. Place a piece of plastic strip across lower half bearing shell (2).7. Install connecting rod cap (1) on connecting rod (7) with two nuts (10). Ensure numbers on

connecting rod cap (1) and connecting rod (7) are aligned.

8. Tighten two nuts (10) as follows:a. Tighten two nuts (10130 lb-ft (41 N•m).b. Tighten two nuts (10) 60 lb-ft (81 N•m).c. Tighten two nuts (10) 90 lb-ft (122 N•m).

9. Remove two nuts (10) and connecting rod cap (1) from connecting rod (9).10. Using plastigage, measure width of plastic strip. Width should be 0.0013-0.0046 in. (0.033-0.117

mm). If width is not within limits, inspect connecting rod journal (11) (task c.).

11. Clean connecting rod cap (1) and install on connecting rod (7) with two nuts (10). Ensure numberson connecting rod (7) and connecting rod cap (1) are aligned.

12. Tighten nuts (10) as follows:a. Tighten two nuts (10) 30 lb-ft (41 N•m).b. Tighten two nuts (10) 60 lb-ft (81 N•m).c. Tighten two nuts (10) 90 lb-ft (122 N•m).

13, Check connecting rod side clearance.

a. Move connecting rod (7) back and forth on connecting rod journal (11).

b. Using feeler gauge, measure connecting rod (7) side clearance. Clearance should be 0.004-0.012 in.(0.1-0.030 mm). If not within limits, remove connecting rod cap (1) and inspect for proper sizeand seating of lower half bearing shell (2), and for dirt or burrs.

c. Repeat steps 12 and 13 to install connecting rod cap (1).

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FOLLOW-ON TASKS: • Install cylinder head (para. 4-41).• Install oil pan and suction tube (para. 4-47).

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5-27. CAMSHAFT AND GEAR MAINTENANCE

THIS TASK COVERS:

a. Check Backlash and End Playb. Removalc. Disassembly


INITIAL SETUP:


SPECIAL TOOLSCam bushing replacement tool

(Appendix E, Item 26)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Gear puller (Appendix E, Item 102)Dial indicator (Appendix E, Item 36)Inside micrometer (Appendix E, Item 82)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)Torque wrench (Appendix E, Item 144)Arbor pressPrybar

MATERIALS/PARTSDowel pin (Appendix D, Item 98)Lockwasher (Appendix D, Item 396)GAA grease (Appendix C, Item 28)Adhesive sealant (Appendix C, Item 4)Rags (Appendix C, Item 58)Drycleaning solvent (Appendix C, Item 71)


EQUIPMENT CONDITION• Engine mounted on repair stand (para. 4-9).• Rocker levers and push rods removed (para. 4-41).• Flywheel housing removed (para. 4-43).• Oil pan and suction tube removed (para. 4-47).• Front gearcase cover removed (para. 4-48).

GENERAL SAFETY INSTRUCTIONS• Keep fire extinguisher nearby when using

drycleaning solvent.• Drycleaning solvent is flammable and toxic. Do

not use near open flame.

a. Check Backlash and End Play

1. Rotate engine block (2) so bottom is facing upward.2. Install dial indicator on engine block (2) and crankshaft gear (1).

NOTEPrevent crankshaft from rotating when checking backlash.Reading will be the total of both gears.

3. Rotate camshaft gear (3) clockwise until teeth contact teeth of crankshaft gear (1).

4. Set dial indicator to zero.

5. Rotate camshaft gear (3) counterclockwise until teeth contact crankshaft gear (1) teeth. Ensurecrankshaft gear (1) does not turn.

6. Backlash of camshaft gear (3) should read 0.005-0.013 in. (0.13-0.33 mm). If reading is not withinlimits, replace camshaft (tasks b through f.).

7. Position dial indicator on face of camshaft gear (3). Press camshaft gear (3) towards rear of engineblock (1).


9. Pull camshaft gear (3) to front of engine block (1).

10. End play of camshaft gear (3) should read 0.006-0.010 in. (0.152-0.254 mm). If reading is not withinlimits, replace camshaft support (tasks b through f).

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b. Removal

1. Install two vibration damper screws (1) on crankshaft (3).2. Using prybar, prevent crankshaft (3) from rotating.3. Remove nut (6) and lockwasher (7) from drive gear (8). Discard lockwasher (7).4. Using gear puller, remove drive gear (8) from fuel injection pump shaft (5).

5. Rotate crankshaft (3) and align timing marks (14) on crankshaft gear (2) and camshaft gear (4).6. Remove two screws (12) from camshaft support (11) and engine block (9).

CAUTION

Use care when removing camshaft. Damage to camshaft andbushings may result.

7. Remove camshaft (13) and camshaft support (11) from engine block (9).NOTE

Tag all valve tappets for installation.

8. Rotate crankshaft (3) as necessary to remove twelve valve tappets (10) from engine block (9).

c. Disassembly

NOTEBefore removing camshaft gear from camshaft, perform task d ofthis procedure. If, as a result of inspection, the camshaft orcamshaft gear requires replacement, perform steps 1 and 2.

1. Using arbor press, press camshaft gear (4) from camshaft (13).2. Remove dowel pin (15) from camshaft (13). Discard dowel pin (15).

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1.2.

3.4.

5.

6.

7.

8.

9.10.

11.

12.13.

14.

WARNING


Clean all camshaft (6) components with drycleaning solvent and dry with clean rag.Inspect camshaft support (1) for wear. Replace camshaft support (1) if excessively worn.

Inspect camshaft (6) for cracks, pits, and breaks. Replace camshaft (6) if cracked, pitted, or broken.

Inspect exhaust (4) and intake (2) camshaft lobes for wear.a. Measure outside diameter of exhaust camshaft lobe (4) at several positions. Replace camshaft (6)

if outside diameter is less than 2.0313 in. (1.5950 mm).b. Measure outside diameter of intake camshaft lobe (2) at several positions. Replace camshaft (6) if

outside diameter is less than 2.0383 in. (51.7728 mm).c. Measure outside diameter of lift pump lobe (5) at several positions. Replace camshaft (6) if

outside diameter is less than 1.626 in. (59.9618 mm).

Inspect camshaft journals (3) for wear. Measure outside diameter of camshaft journals (3) at severalpositions. Replace camshaft (6) if outside diameter is less than 2.3067 in. (59.9618 mm).Inspect camshaft gear (7) for cracks, pits, and breaks. Replace camshaft gear (7) if cracked, pitted,or broken.Inspect camshaft gear teeth (8) for pitting and cracks at root of teeth (8). Replace camshaft gear (7)if pitted or cracked.Inspect camshaft bushings (9) for wear. Measure inside diameter of camshaft bushing (9) at severalpositions. If inside diameter exceeds 2.367 in. (60.122 mm), mark camshaft bushing (9) forreplacement.

NOTEPerform steps 9 through 14 for replacing camshaft bushings.

Remove expansion plug (11) from rear of engine block (10). Discard expansion plug (11).Using cam bushing replacement tool, remove camshaft bushing (9) from bushing bore (14). Discardcamshaft bushing (9).

Measure inside diameter of camshaft bores (14). Replace engine block (10) if inside diameterexceeds 2.520 in. (64.008 mm).

CAUTION

When installing camshaft bushing, ensure oil hole and oil holepassages are aligned. Failure to do so will result in prematurefailure and damage to engine.

Mark engine block (10) and new camshaft bushing (9) to ensure oil holes (12) and (13) are aligned.Using cam bushing replacement tool, install new camshaft bushing (9) in camshaft bushing bore (14).

NOTEPerform step 14 if rear camshaft bushing was removed.

Apply adhesive sealant to mating surfaces of new expansion plug (11) and install on engine block (10).

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15. Inspect valve tappets (2) for nicks, burrs, and wear. Replace tappet(s) (2) if nicked, burred, or worn.16. Measure outside diameter of tappet stem (1). Replace tappet(s) (2) if outside diameter is less than

0.628 in. (15.95 mm).17. Inspect tappet bores (8) for scoring and wear. Replace engine block (7) if excessively scored or worn.18. Measure inside diameter of tappet bore (8). Replace engine block (7) if inside diameter exceeds

0.632 in. (16.05 mm).

NOTEPerform steps 1 through 3 if camshaft gear was removed.

1. Install new dowel pin (3) in camshaft (4).2. Apply GM grease to coat camshaft lobe (5).

3. Using arbor press, press camshaft gear (6) on camshaft (4).

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f. Installation

NOTE• Used valve must be installed in mating tappet bores. If valve

tappet position was not noted during removal, replace all valvetappets.

• Do not reuse old valve tappets if installing new camshaft.

1. Rotate crankshaft (10) as necessary to access tappet bores (8).2. Coat twelve tappets (2) with GAA grease and install in tappet bores (8).

CAUTION

Use care when installing camshaft. Camshaft and bushings areeasily damaged.

3. Apply coat of GM grease to camshaft (4) and install in engine block (7). Ensure timing marks (13)of camshaft gear (6) and crankshaft gear (9) are aligned.

4. Install camshaft support (11) on engine block (7) with two screws (12). Tighten screws (12) 18 lb-ft(24 N•m).

5. Check backlash and end play of camshaft (4) for proper seating (task a).

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6.7.

8.

Using prybar between two vibration damper screws (1), rotate crankshaft (2).Press in timing pin (15), while rotating crankshaft (2), until timing pin (15) engages camshaftgear (3).Remove access plug (9), copper washer (8), and fuel injection pump timing pin (10) from fuelinjection pump (11).

9. Install nut (4) on fuel injection pump shaft (12) and rotate until timing tooth (14) is visible in timingpin hole (13).

10.

11.12.

Install fuel injection pump timing pin (10) in hole (13). Ensure slot (7) of fuel injection pump timingpin (10) is positioned over timing tooth (14).Install copper washer (8) and access plug (9) on fuel injection pump (11).Remove nut (4) from fuel injection pump shaft (12).

NOTEDo not exceed torque limit for fuel injection pump drive gear nut.Torque is not the final limit.

13. Install drive gear (6) on fuel injection pump shaft (12) with new lockwasher (5) and nut (4). Tightennut (4) 7-11 lb-ft (10-15 N•m).

14.15.16.

Disengage timing pin (15) from camshaft gear (3).Remove access plug (9), copper washer (8), and timing pin (10) from fuel injection pump (11).Install timing pin (10) in fuel injection pump (11) with slot (7) facing outward from fuel injectionpump (11).

17. Install copper washer (8) and access plug (9) on fuel injection pump (11).18. Using prybar between two vibration damper screws (1), tighten nut (4) 80 lb-ft (109 N•m).

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FOLLOW-ON TASKS: • Install oil pan and suction tube (para. 4-47).• Install front gearcase cover (para. 4-48).• Install flywheel housing (para. 4-43)• Install rocker levers and push rods tpara. 4-41)• Remove engine from repair stand (para. 4-9).

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5-28. CYLINDER LINERS AND BLOCK MAINTENANCE

THIS TASK COVERS:

a. Cylinder Liner Inspectionb. Cylinder Liner Removalc. Engine Block Disassembly

d. Cylinder Liner and Engine Block Cleaningand Inspection

e. Engine Block Assemblyf. Cylinder Liner Installation

INITIAL SETUP:



SPECIAL TOOLS EQUIPMENT CONDITIONCylinder liner puller (Appendix E, Item 107) • Connecting rods and pistons removed (para. 5-26).Cylinder liner driver (Appendix E, Item 79) • Camshaft removed (para. 5-27).Two cylinder liner clamps (Appendix E, Item 35) • Crankshaft removed (para. 5-29).

TOOLS GENERAL SAFETY INSTRUCTIONSGeneral mechanic’s tool kit (Appendix E, Item 1) • Keep fire extinguisher nearby when usingInside micrometer (Appendix E, Item 83) drycleaning solvent.Gauge block (Appendix E, Item 52) • Drycleaning solvent is flammable and toxic.Torque wrench (Appendix E, Item 144) • Eyeshields must be worn when cleaning withDial indicator (Appendix E, Item 36) compressed air. Compressed air source will notTelescoping gauge (Appendix E, Item 136) exceed 30 psi (207 kPa).Feeler gauge

MATERIALS/PARTSCylinder block kit (Appendix D, Item 93)Cylinder liner seal (Appendix D, Item 95)Drycleaning solvent (Appendix C, Item 71)Rags (Appendix C, Item 58)Crocus cloth (Appendix C, Item 20)Detergent (Appendix C, Item 27)Lubricating oil (Appendix C, Item 50)Antiseize tape (Appendix C, Item 72)Adhesive sealant (Appendix C, Item 4)

a. Cylinder Liner Inspection

CAUTION

Do not hone or deglaze cylinder liners. Honing or deglazing willprevent oil ring from sealing properly.

NOTEInspect all cylinder liners to determine need for replacement.

1. Inspect cylinder liner (1) for vertical scratches, grooves, pits, scuffing, scoring, and cracks. Tagcylinder liner (1) for replacement if scratched, grooved, pitted, scuffed, scored, or cracked.

2. Inspect for dirt or debris embedded in walls of cylinder liner (1). Tag cylinder liner (1) forreplacement if debris is present.

3. Inspect walls of cylinder liner (1) for heavy polishing and wear. Heavy polishing exists when wallhas a bright mirrored finish. Tag cylinder liner (1) for replacement if heavy polishing exists.

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4 . Check cylinder liner (1) for wear:a. Measure inside diameter of cylinder liner (1) in two places offset 90° at top of piston travel.b. Record inside diameter measurements A and B.

c. Measure inside diameter of cylinder liner (1) in two places offset 90° at bottom of piston travel.d. Record inside diameter measurements C and D.

e. Compare inside diameter measurements A with B and C with D. Tag cylinder liner (1) forreplacement if difference exceeds 0.0016 in. (0.041 mm).

f. Compare inside diameter measurements A with D and B with C. Tag cylinder liner (1) forreplacement if difference exceeds 0.0016 in. (0.041 mm).

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b. Cylinder Liner Removal

NOTEAll cylinder liners are removed the same way. This procedurecovers the removal of one cylinder liner.

1. Scribe a mark (3) across cylinder liner (2) and engine block (4) for installation.

CAUTION

Do not install cylinder liner puller on lower block ledges. Failureto comply may cause damage to engine block.

NOTETag all cylinder liners with mating cylinder bore number forinstallation.

2. Install cylinder liner puller on engine block (4) and cylinder liner (2). Ensure cylinder liner pullerdoes not catch on lower block ledges (5).

3. Remove cylinder liner (2) from engine block (4).4. Remove cylinder liner seal (1) from cylinder liner (2). Discard cylinder liner seal (1).

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c. Engine Block Disassembly

NOTEMark position and location of pipe and expansion plugs forinstallation.

1. Remove expansion plug (1) from engine block (2). Discard expansion plug (1).

2. Remove three expansion plugs (12) from engine block (2). Discard expansion plugs (12).3. Remove two expansion plugs (11) from engine block (2). Discard expansion plugs (11).

4. Remove drainvalve (10) from engine block (2).5. Remove expansion plug (4) from engine block (2). Discard expansion plug (4).6. Remove pipe plugs (5) and (9) from engine block (2).7. Remove expansion plug (6) from engine block (2). Discard expansion plug (6).8. Remove expansion plug (7) from engine block (2). Discard expansion plug (7).9. Remove expansion plug (8) from engine block (2). Discard expansion plug (8).

NOTEPerform step 10 if dowel pins are damaged.

10. Remove four dowel pins (3) from engine block (2). Discard dowel pins (3).11. Remove three pipe plugs (16) from engine block (2).12. Remove expansion plugs (13) and (17) from engine block (2). Discard expansion plugs (13) and (17).

13. Remove expansion plug (15) from engine block (2). Discard expansion plug (15).

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NOTEPerform step 14 if dowel pins are damaged.

14. Remove two dowel pins (14) from engine block (2). Discard dowel pins (14).

15. Remove six piston cooling nozzles (18) from engine block (2).NOTE

Perform step 16 for late model engine.

16. Remove twelve piston cooling nozzles (18) from engine block (2).

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d. Cylinder Liner and Engine Block Cleaning and Inspection

1.2.

3.4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

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WARNING

• Drycleaning solvent is flammable and toxic. Do not use near anopen flame and always have a fire extinguisher nearby whensolvents are used. Use only in well-ventilated places, wearprotective clothing, and dispose of cleaning rags in approvedcontainer. Failure to do this may result in injury or death topersonnel and/or damage to equipment.

• Eyeshields must be worn when cleaning with compressed air.Compressed air source will not exceed 30 psi (207 kPa). Failureto do so may result in injury to personnel.

CAUTION

• Do not allow debris to fall into crankshaft oil holes. Damage tocrankshaft bearings could result.

• Do not remove stock material from cylinder liner seatingsurface when cleaning. Machined tolerances are critical andpremature engine failure will result if material is removed.

Cover crankshaft oil holes (6) with clean rags.Clean all expansion plug holes of engine block (2) with drycleaning solvent. Dry with compressedair.Clean sealing surfaces (3), (4), and (5) of engine block (2) with crocus cloth and drycleaning solvent.Inspect sealing surfaces (3), (4), and (5) for cracks, pits, scores, and excessive wear. Replace engineblock (2) if cracked, pitted, scored, or excessively worn.

Measure inside diameter of sealing surface (4). Replace engine block (2) if inside diameter exceeds5.2342 in. (132.949 mm).Clean all oil draining and water cooling passage bores with brush and drycleaning solvent. Dry withcompressed air.

CAUTION

Engine block deck can be resurfaced twice in increments of0.010 in. (0.254 mm). Do not exceed 0.020 in. (0.508 mm) whenresurfacing or damage to equipment will result.

Using straight edge and feeler gauge, inspect engine block (2) deck for warping. Replace engineblock (2) if warping exceeds 0.008 in. (0.203 mm). Notify your supervisor.

Install seven main bearing caps (8) on engine block (2) with fourteen screws (9). Tightenscrews (9) 130 lb-ft (176 N•m).Using bore gauge, measure inside diameter of main bearing bore (10). Record measurement.Replace main bearing (7) if inside diameter exceeds 3.8632 in. (98.125 mm).Using bore gauge, measure inside diameter of camshaft bore (12). Replace bushing (13) if insidediameter exceeds 2.367 in. (60.12 mm).

Measure inside diameter of tappet bore (11). Replace engine block (2) if inside diameter exceeds0.632 in. (16.05 mm).

NOTECylinder liners should be inspected before cleaning so defects canbe clearly noted.

Check cylinder liner (1) for cracks, scoring, or vertical grooves. Replace cylinder liner (1) if cracked,scored, or vertical grooves are present.

Check cylinder liner (1) for pits and eroded surfaces. Replace cylinder liner (1) if pitted or eroded.

TM 9-2320-272-24-4


14. Check cylinder liner (1) for fretting and breaks in machined areas. Replace cylinder liner (1) iffretted or broken.

15. Check cylinder liner (1) for rust, scaling, and corrosion.a. Clean with steam or hot water and detergent.b. Replace if excessively rusted, scaled, or corroded.

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e. Engine Block Assembly

CAUTION

Ensure all engine block oil passages are free of obstructions.Failure to do so may result in damage to engine.

NOTE• Perform step 1 for late model engines, serial

number 44487830 and after.• Perform step 2 if dowel pins were removed.

1. Install twelve piston cooling nozzles (7) in engine block (2).

2. Install two new dowel pins (3) in engine block (2).3. Install six piston cooling nozzles (7) in engine block (2).

NOTE• Apply adhesive sealant to mating surfaces of all expansion

plugs before installation.• Wrap male pipe threads with antiseize tape before installation.

4. Install new expansion plug (4) in engine block (2).5. Install new expansion plugs (6) and (1) on engine block (2).

6. Install three pipe plugs (5) on engine block (2). Tighten pipe plugs (5) 6 lb-ft (8 N•m).

NOTEPerform step 7 if dowel pins were removed.

7. Install four new dowel pins (8) on engine block (2).8. Install new expansion plug (13) on engine block (2).9. Install new expansion plug (12) on engine block (2).

10. Install new expansion plug (11) on engine block (2).

11. Install pipe plugs (10) and (14) on engine block (2). Tighten pipe plug (14) 6 lb-ft (8 N•m). Tightenpipe plug (10) 27 lb-ft (37 N•m).

12. Install new expansion plug (9) on engine block (2).13. Install new drainvalve (15) on engine block (2).14. Install two new expansion plugs (16) on engine block (2).

15. Install three new expansion plugs (17) on engine block (2).16. Install new expansion plug (18) on engine block (2).

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f. Cylinder Liner Installation

NOTEAll cylinder liners are installed the same. This procedure coversinstallation of one cylinder liner.

1. Apply clean engine oil to lubricate cylinder liner bore (4).

2. Install new cylinder liner seal (2) on cylinder liner (1).3. Apply clean engine oil to lubricate sealing surfaces (5), (6), and (7), cylinder liner (1), and cylinder

liner seal (2).4. Install cylinder liner (1) in mating cylinder liner bore (4).

NOTEPerform step 5 if installing old cylinder liner.

5. Rotate cylinder liner (1) 1/8 turn from position noted in removal. Using cylinder liner driver, drivecylinder liner (1) until it bottoms in cylinder liner bore (4).

6. Install two cylinder liner clamps on engine block (3) with two washers and screws. Tighten screws50 lb-ft (68 N·m).

7. Remove two screws, washers, and cylinder liner clamps from engine block (3).8. Using gauge block, measure cylinder liner protrusion:

a. Position gauge block on engine block (3).b. Place plunger on engine block (2) and set dial indicator to zero.c. Position gauge block on engine block (3) and place plunger on cylinder liner (1).d. Cylinder liner protrusion should be 0.005-0.0043 in. (0.0127-0.1092 mm).e. Check cylinder liner (1) for proper installation if cylinder liner protrusion is not within limits.f. If installed correctly, counterbore of engine block (3) will require cutting. Notify your supervisor.

9. Check clearance between cylinder liner (1) and lower block ledges (8) using 0.009 in. (0.229 mm)feeler gauge. If feeler gauge does not pass between cylinder liner (1) and lower bottom ledges (8),remove cylinder liner (1) and reinstall.

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FOLLOW-ON TASKS: Install connecting rods and pistons (para. 5-26).Install crankshaft (para. 5-29).Install camshaft (para. 5-27).

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5-29. CRANKSHAFT AND GEAR MAINTENANCE

THIS TASK COVERS:a. Check End Play d. Cleaning and Inspectionb. Removal e. Assemblyc . Disassembly f . Installation

INITIAL SETUP:

APPLICABLE MODELS REFERENCES (TM)

M939A2 TM 9-2320-272-24P

SPECIAL TOOLS EQUIPMENT CONDITIONTorque angle gauge (Appendix E, Item 141) Fuel injectors removed (para. 4-55).

TOOLSOil pan and suction tube removed (para. 4-47).

General mechanic’s tool kit (Appendix E, Item 1)Front gearcase housing removed (para. 4-46).Flexplate and flywheel housing removed

Heavy duty gear puller (Appendix E, Item 102) (para. 4-43).Dial indicator (Appendix E, Item 36) Rear cover and oil seal removed (para. 4-44).Torque wrench (Appendix E, Item 144)Feeler gauge GENERAL SAFETY INSTRUCTIONSPrybar Drycleaning solvent is flammable and toxic. DoSoft-head hammer not use near open flame.Nylon brush Keep fire extinguisher nearby when using

MATERIALS/PARTSdrycleaning solvent.Eyeshields must be worn when cleaning with

Dowel pin (Appendix D, Item 99) compressed air. Compressed air source will notCrankshaft main bearing set

(Appendix D, Item 87)exceed 30 psi (207 kPa).

Drycleaning solvent (Appendix C, Item 71)GAA grease (Appendix C, Item 28)Lubricating oil (Appendix C, Item 50)Plastigage (Appendix C, Item 55)Crocus cloth (Appendix C, Item 20)

a. Check End Play

1. Position engine block (2) so crankshaft (1) is facing upward.2. Install dial indicator on engine block (2) with plunger on face of crankshaft gear (3).

3. Move crankshaft (1) towards rear of engine block (2) using prybar.


5. Move crankshaft (1) toward front of engine block (2) using prybar. Record dial indicator reading.

6. Replace thrust bearing in subtasks b and f if crankshaft (1) end play is not between 0.006-0.013 in.(0.152-0.330 mm).

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5-29. CRANKSHAFT AND GEAR MAINTENANCE (Contd)

b. Removal

NOTETag all connecting rod caps, main bearing caps, matingcylinders, and bearings for installation.

All connecting rod caps and main bearing caps are removed thesame.

1. Remove twelve nuts (5) from six connecting rod caps (4).2. Using soft-head hammer, tap screws (6) and remove connecting rod caps (4) from crankshaft (1).3. Remove fourteen screws (8) from seven main bearing caps (9).4. Loosen main bearing caps (9) and remove from crankshaft (1) using screws (8).5. Remove seven lower main bearings (7) from main bearing caps (9). Discard bearings (7).6. Remove crankshaft (1) from engine block (2).

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7. Remove six upper main bearings (5) and thrust bearing (6) from engine block (4). Discardbearings (5) and (6).

NOTEPerform step 8 for late model engines, serial number 44487830and after.

8. Remove twelve piston cooling nozzles (7) from engine block (4).9. Remove six piston cooling nozzles (7) from engine block (4).

c. Disassembly

NOTEBefore removing crankshaft gear from crankshaft, performsubtask d of this procedure. If, as a result of inspection, thecrankshaft gear must be removed, perform steps 1 and 2.

1. Using gear puller, remove crankshaft gear (3) from crankshaft (1).2. Remove dowel pin (2) from crankshaft (1). Discard dowel pin (2).

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1.

2.

3.

4.

Drycleaning solvent is flammable and toxic. Do not use nearopen flame and always have a fire extinguisher nearby whensolvents are used. Use only in well-ventilated places, wearprotective clothing, and dispose of cleaning rags in approvedcontainer. Failure to do this may result in injury or death topersonnel and/or damage to equipment.Eyeshields must be worn when cleaning with compressed air.Compressed air source will not exceed 30 psi (207 kPa). Failureto do so may result in injury to personnel.

Clean all parts with drycleaning solvent and dry with compressed air. Use nylon brush to clean alloil passages.Inspect crankshaft (1) for cracks, gouges, pits, burrs, nicks, and scratches. Remove minor damagewith fine mill file or crocus cloth. If excessively cracked, gouged, pitted, burred, nicked, or scratched,replace crankshaft (1).Inspect crankshaft gear (3) for cracks, breaks, and damaged teeth. If cracked, broken, or teeth aredamaged, replace crankshaft gear (3).Inspect connecting rod journals (9) and main bearing journals (8) for scratches, grooves, excessivewear, and discoloring caused by overheating. Replace crankshaft (1) if scratched, grooved, worn, ordiscolored.

WARNING

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5.

6.

7.

8.

9.

10.

11.

12.

13.14.

15.16.17.

Inspect connecting rod caps (14) for cracks, breaks, and pits. Replace connecting rod caps (14) ifcracked, broken, or pitted.

Inspect main bearing caps (7) for cracks, breaks, and pits. Replace main bearing caps (7) if cracked,broken, or pitted.Inspect engine block (9) for scratches, grooves, wear, and stripped threads. Replace or repair ifengine block (9) is scratched, grooved, worn, or threads are stripped.Measure outside diameter of main bearing journals (2) for out-of-roundness across points A and B.Replace crankshaft (1) if difference of measurements exceeds 0.002 in. (0.0051 mm).

Measure outside diameter of main bearing journals (2) for taper at points C and D. Replacecrankshaft (1) if difference of measurements exceeds 0.0005 in. (0.013 mm).

Measure outside diameter of connecting rod journals (3) for out-of-roundness across points A and B.Replace crankshaft (1) if difference of measurements exceeds 0.002 in. (0.0050 mm).Measure outside diameter of connecting rod journals (3) for taper at points C and D. Replacecrankshaft (1) if difference of measurements exceeds 0.0005 in. (0.0127 mm).Inspect front (4) and rear (5) crankshaft seal wear surfaces for scratches and grooves. Replacecrankshaft (1) if scratched or grooved.

CAUTION

Ensure main bearings are installed in proper mating seats.Failure to do so will cause engine to fail.

Install new thrust bearing (8) in No. 4 main bearing seat (11).Install six new upper main bearings (7) in main bearing seats (10). Ensure tangs (12) of upper mainbearings (7) are aligned with slots (13) of main bearings seats (10).Install crankshaft (1) in engine block (9).

Install seven new lower main bearings (6) in main bearing caps (7).Place plastic strips across width of seven main bearing journals (2).

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NOTEEnsure main bearing caps are installed with mating cylinders.Number on main bearing caps should face camshaft.

18. Apply clean engine oil to coat threads of fourteen screws (2).

19. Position seven main bearing caps (3) on engine block (14) and crankshaft (7) and tap main bearingcaps (3) using soft-head hammer until seated on main bearing journals (6).

20. Install main bearing caps (3) on engine block (14) with fourteen screws (2). Tighten screws (2)125 lb-ft (170 N·m) in sequence shown.

21. Remove fourteen screws (2) and seven main bearing caps (3) from engine block (14).22. Measure width of plastic strip at widest point using plastigage. If plastic strip does not measure

0.0026-0.0053 in. (0.660-0.1346 mm), replace all upper (10), lower (1), and thrust (11) bearings.

e. Assembly

NOTEPerform steps 1 through 3 if gear was removed.

1. Install new dowel pin (5) in crankshaft (7).2. Apply GAA grease to lobe (8) of crankshaft (7).3. Press crankshaft gear (9) on crankshaft (7).

f. Installation

CAUTION

Late and early model engine main bearings and main bearing capsand components are not interchangeable. Mixing components willcause damage to engine.

NOTEPerform step 1 if inspection did not require replacement of mainbearings.Perform step 3 for late model engines, serial number 44487830and after.

Piston cooling nozzles are located in all upper chain bearingseats, except for No. 3 cylinder.

1. Remove six upper main bearings (10) and thrust bearing (11) from engine block (14).2. Install six piston cooling nozzles (15) in upper main bearing seats (12). Ensure piston cooling

nozzles (15) seat below main bearing surface.3. Install twelve piston cooling nozzles (15) in upper main bearing seats (12). Ensure piston cooling

nozzles (15) seat below main bearing surface.NOTE

Apply lubricating oil to all main bearings and bearing surfaces.

4. Align tangs (16) of six upper main bearings (10) with slots (17) of main bearing seats (12) andinstall on engine block (14).

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5. Install thrust bearing (11) in No. 4 main bearing seat (13).

6. Install crankshaft (7) in engine block (14).NOTE

Perform step 7 if inspection required replacement of lower mainbearings.

7.

8.

9.10.

11.

12.13.

Align tangs (4) of seven lower main bearings (1) with slots of main bearing caps (3) and installseven lower main bearings (1) in main bearing caps (3).Apply clean engine oil to main bearing journals (6) and install seven main bearing caps (3) onengine block (14).Using soft-head hammer, tap main bearing caps (3) until seated against main bearing journals (6).Apply clean engine oil to threads of fourteen screws (2) and install on main bearing caps (3).

Tighten screws (2) as follows:

a. Tighten screws (2) 125 lb-ft (170 N·m) in sequence shown. Loosen screws (2).

b. Tighten screws (2) to 70 lb-ft (95 N·m) in sequence shown.c. Using torque angle gauge, tighten screws (2) an additional 45-75°.Rotate crankshaft (7) and check for freedom of movement.Check crankshaft (7) end play (task a).

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14.

15.

16.17.18.

19.20.

21.22.

23.

Place a piece of plastic strip across width of connecting rod cap (1).

Install connecting rod cap (1) on crankshaft (2) and connecting rod (3) with two nuts (4).

Tighten nuts (4) 30 lb-ft (41 N·m), then 60 lb-ft (81 N·m), then 90 lb-ft (122 N·m).Remove two nuts (4) and connecting rod cap (1) from connecting rod (3) and crankshaft (2).Using plastigage, measure width of plastic strip. If width is not 0.0013-0.0046 in.(0.033-0.117 mm), replace all connecting rod bearings (5) and (6).Apply clean engine oil to lubricate connecting rod cap (1).Install connecting rod cap (1) on crankshaft (2) and connecting rod (3) with two nuts (4).Tighten nuts (4) 30 lb-ft (41 N·m), then 60 lb-ft (81 N·m), then 90 lb-ft (122 N·m).

Move connecting rod (3) back and forth on crankshaft (2).

Measure connecting rod (3) side clearance using feeler gauge. If clearance is not 0004-0.012 in.(0.1-0.30 mm), remove connecting rod cap (1) and inspect for proper size and seating ofbearings (5) and (6).

NOTEAll connecting rod caps are installed the same. This procedurecovers the installation of one connecting rod cap.Rotate crankshaft as necessary to access connecting rodjournals.

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FOLLOW-ON TASKS: Install rear cover and oil seal (para. 4-44).Install flexplate and flywheel housing (para. 4-43).Install front gearcase housing (para. 4-46).Install oil pan and suction tube (para. 4-47).Install fuel injectors (para. 4-55).

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5-30. ROCKER LEVERS AND PUSH RODS MAINTENANCE

THIS TASK COVERS:a. Disassembly c. Assemblyb. Cleaning and Inspection

INITIAL SETUP:


TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Inside micrometer (Appendix E, Item 82)Outside micrometer (Appendix E, Item 80)Torque wrench (Appendix E, Item 144)

MATERIALS/PARTSTwelve locknuts (Appendix D, Item 326)Drycleaning solvent (Appendix C, Item 71)Lubricating oil (Appendix C, Item 50)

REFERENCES (TM)TM 9-2320-272-10TM 9-2320-272-24P

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Rocker-levers and push rods removed (para. 4-41).

GENERAL SAFETY INSTRUCTIONSKeep fire extinguisher nearby when usingdrycleaning solvent.Drycleaning solvent is flammable and toxic.Eyeshields must be worn when cleaning withcompressed air. Compressed air source will notexceed 30 psi (207 kPa).

a. Disassembly

NOTEAll rocker levers are disassembled the same way. This procedurecovers one rocker lever assembly.

1. Remove two retaining rings (2), washers (3), spring washers (4), and rocker levers (1) from rockershaft (7).

2. Remove locknut (5) and adjusting screw (6) from each rocker lever (1). Discard locknut (5).


1. For general cleaning instructions, refer to para. 2-14

2. For general inspection instructions, refer to para. 2-15.

3. Replace all parts failing inspection.4. Measure inside diameter of rocker lever bore (8) at several points, If inside diameter exceeds

0.878 in. (22.3 mm), replace rocker lever (1).5. Measure outside diameter of rocker shaft (7) at several points. If outside diameter is less than 0.874

in. (22.2 mm), replace rocker shaft (7).

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5-30. ROCKER LEVERS AND PUSH RODS MAINTENANCE (Contd)

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Drycleaning solvent is flammable and toxic. Do not use nearopen flame and always have a fire extinguisher nearby whensolvents are used. Use only in well-ventilated places, wearprotective clothing, and dispose of cleaning rags in approvedcontainer. Failure to do this may result in injury or death topersonnel and/or damage to equipment.Eyeshields must be worn when cleaning with compressed air.Compressed air source will not exceed 30 psi (207 kPa). Failureto do so may result in injury to personnel.

6. Inspect oil manifold (2) for bends, cracks, and breaks. If bent, cracked, or broken, replace oilmanifold (2).

CAUTION

Oil manifold screws are self-tapping and must be reinstalled intheir proper positions to ensure proper alignment of screw flats ordamage may occur to oil manifold.

7. Inspect oil manifold (2) for clogged oil ports. If oil ports are clogged, remove two screws (1), flush oilmanifold (2) with drycleaning solvent. Dry with compressed air and replace two screws (1) in oilmanifold (2).

d. Assembly

All rocker levers are assembled the same way. This procedure isfor one rocker lever assembly.Lightly oil all parts before assembling.Perform step 1 if assembling with new rocker shaft.

1. Install two plugs (8) on rocker shaft (13).

2. Install adjusting screw (12) and new locknut (7) on each rocker lever (6).

3. Install spring washer (5), washer (4), and retaining ring (3) on one side of rocker shaft (13).

4. Install two rocker levers (6) on rocker shaft (13).

5. Install spring washer (11), washer (10), and retaining ring (9) on rocker shaft (13).

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FOLLOW-ON TASK: Install rocker levers and push rods (para. 4-41).

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5-31. MOUNTING FUEL INJECTION PUMP TO TEST STAND

THIS TASK COVERS:a. Mounting Fuel Injection Pump to b. Removing Fuel Injection Pump from

Test Stand Test Stand

INITIAL SETUP:

APPLICABLE MODELS MATERIALS/PARTSM939A2 Lockwasher (Appendix D, Item 383)

TOOLSTwo copper washers (Appendix D, Item 42)

General mechanic’s tool kit (Appendix E, Item 1)Copper washer (Appendix D, Item 45)Copper washer (Appendix D, Item 44)

Fuel injection pump test stand (Appendix E,Item 50) REFERENCES (TM)

TM 9-2320-272-24P

EQUIPMENT CONDITIONFuel injection pump removed (para. 4-57).

a. Mounting Fuel Injection Pump to Test Stand

1. Remove screw plug (11) and copper washer (12) from drive end of fuel pump (14). Discard copperwasher (12).

2. Install adapter ring (23) on adapter bracket (6) with three washers (9) and screws (10).3. Install adapter bracket (6) on test stand (20) with washer (7), screw (8), and clamp bar (25).4. Install fuel pump (14) on adapter bracket (6) with four washers (26), screws (27), washers (22), and

nuts (21).

5. Install woodruff key (13) and drive hub (3) on fuel pump (14) with lockwasher (2) and nut (1).6. Slide fuel pump (14) forward so drive hub (3) engages with drive coupling (28) and secure fuel

pump (14) in place with four lockwashers (4) and nuts (5).7. Install rear support bracket (19) on rear of fuel pump (14) with two washers (17) and screws (18).

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5-31. MOUNTING FUEL INJECTION PUMP TO TEST STAND (Contd)

8. Install rear support bracket (19) and clamp bar (24) on test stand (20) with two washers (16) andscrews (15).

9. Connect six test stand fuel lines (30) to delivery valve holders (29) and test stand injectors.10. Connect air line (32) to manifold pressure compensator (31).

11. Remove plug (36), two copper washers (35), and adapter (37) from fuel pump (14). Discard copperwashers (35).

12. Install outlet elbow (34) on fuel pump (14).

13. Connect test stand supply line (33) to outlet elbow (34).

14. Remove plug (38) and copper washer (39) from side of fuel pump (14) for access to number onecylinder. Discard copper washer (39).

15. Refer to table 5-10, Test Stand Requirements, for further preliminary requirements.

Table 5-10. Test Stand Requirements.

ITEM REQUIREMENTS

Calibration Fluid Temperature 100°-108°F (38°-42°C)

Inlet Pressure 22 psi (152 kPa)

Opening Pressure 3,000-3,046 psi (20,684-21,001 kPa)

Firing Order 1-5-3-6-2-4

Select Drive Rotation 1:2

Direction of Drive Rotation Clockwise

Number of Injection Cylinders Six

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b. Removing Fuel Injection Pump from Test Stand

1. Install new copper washer (10) and plug (9) on fuel pump (11).2. Disconnect test stand supply line (4) from outlet elbow (5).

3. Remove outlet elbow (5) from fuel pump (11).4. Install two new copper washers (6), adapter (8), and plug (7) on fuel pump (11).5. Disconnect air line (3) from manifold pressure compensator (2).6. Disconnect six test stand fuel lines (1) from delivery valve holders (12).

7. Remove two screws (29) and washers (28) from rear support bracket (30).8. Remove four nuts (17) and lockwashers (16) from drive coupling (39). Discard lockwashers (16).

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9.10.11.

12.13.14.15.16.

Remove four nuts (32), washers (33), screws (38), and washers (37) from adapter bracket (18).Loosen screw (20) and slide fuel pump (11) from drive coupling (39).Remove nut (13), lockwasher (14), drive hub (15), and woodruff key (25) from fuel pump (11).Discard lockwasher (14).

Remove fuel pump (11) from adapter bracket (18) and test stand (31).Install new copper washer (22) and screw plug (21) on fuel pump (11).Remove three screws (24), washers (23), and adapter ring (34) from adapter bracket (18).Remove screw (20), washer (19), adapter bracket (18), and clamp bar (36) from test stand (31).Remove two screws (26), washers (27), rear support bracket (30), and clamp bar (35) from teststand (31).

FOLLOW-ON TASK: Install fuel injection pump (para. 4-57).

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5-32. FUEL INJECTION PUMP PRETEST

THIS TASK COVERS:a. Prestroke and Rack Travelb. Cylinder Phasing (Timing)c. High-speed Fuel Delivery Test

g. Manifold Pressure Compensator Testh. Start Cut Out TestI. Fuel Delivery Test

d. Low-speed Fuel Delivery Test j. Fuel Breakaway Teste. Rated Speed Test k. Starting Fuel Delivery Testf. Full Load Delivery l. Low Idle Fuel Delivery Test

INITIAL SETUP:

APPLICABLE MODELS MATERIALS/PARTSM939A2 Two copper washers (Appendix D, Item 42)

SPECIAL TOOLS REFERENCES (TM)Rack extension (Appendix E, Item 112) TM 9-2320-272-24PPlunger lift device (Appendix E, Item 98) TM 9-4910-778-14&P

TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1)Dial Indicator (Appendix E, Item 36)

Fuel injection pump mounted to test stand (para. 5-31).

NOTERefer to TM 9-4910-778-14&P for operation of fuel injectionpump test stand, DFP 156.If readings taken during pretest deviate from specificationslisted below, fuel pump must be repaired.

a. Prestroke and Rack Travel

1.2.3.

4.

5.

6.

7. Mount dial indicator (4) on plunger lift device (5) and zero dial indicator (4).8. Manually rotate test stand driveshaft (8) until a reading is observed on dial indicator (4).

9. Manually reverse rotation test stand driveshaft (8) until dial indicator (4) reads zero.

10. Apply 435-464 psi (2,999-3,190 kPa) of calibration fluid pressure.

Mount dial indicator (10) and rack travel indicator holder (9) on drive end of fuel pump (13).Install rack extension (11) on control rack (12).

Pull control lever (2) to full load position and, using rack extension (11), push control rack (12) allthe way back.Preload dial indicator (10) giving control rack (12) 0.004 in. (0.1 mm) of preload travel.

Install plug (3) in return line access hole (14).NOTE

Cylinder number one is located at drive end of fuel pump.Rotate test stand driveshaft until tappet reaches bottom deadcenter.

Install plunger lift device (5) on fuel pump (13) with finger of plunger lift device (5) resting on top oftappet located in cylinder number one.

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5-32. FUEL INJECTION PUMP PRETEST (Contd)

NOTEEnsure a steady stream of calibration fluid flows from all bleed-offvalves. If not, increase calibration fluid pressure until a steadystream of calibration fluid is obtained.

11. Manually rotate test stand driveshaft (8) in correct fuel pump rotation until calibration fluid stopsflowing from bleed-off valve (1).

12. Check prestroke measurement. Measurement should be 0.360-0.480 in. (9.14-12.19 mm).13. Remove plunger lift device (5) and dial indicator (4) from fuel pump (13).

14. Install copper washer (7) and plug (6) on fuel pump (13).

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b. Cylinder Phasing (Timing)

1.2.3.4.5.

6.

7.

In order to perform this task, correct prestroke measurement mustbe obtained for cylinder number one (task a).

Set protractor (1) on drive end of test stand (6) to zero.Remove plug (7) from fuel pump (4).Install two new copper washers (5), plug (7), and adapter (8) on fuel pump (4).Connect test stand return line (2) to fuel pump adapter (8).Apply 435-464 psi (2,999-3,199 kPa) of calibration fluid pressure to fuel pump (4).

Manually rotate test stand driveshaft (3) in correct rotation of fuel pump (4) until calibration fluidstops flowing from number five bleed-off valve.

Observe reading on protractor (1). Correct reading should be 60°.

NOTE

8.9.

10.

11.

Following fuel pump firing order 1-5-3-6-2-4, repeat steps 6and 7 until remaining cylinders are phased (timed).For each cylinder phased, test stand protractor will increase in60° intervals.Perform steps 8 through 11 if 60° interval is not obtained.Perform steps 8 through 11 to adjust one cylinder. Adjustmentof remaining five cylinders is performed basically the same way.

Remove fuel test line (9) from delivery valve holder (10).Loosen three nuts (11) and remove two shims (12) between barrel (13) and fuel pump (4). Discardshims (12).

CAUTION

Shims of the same thickness must be used on both sides of barrel.Failure to do so will result in inaccurate prestroke measurement.

NOTERefer to TM 9-2320-272-24P to select shims.

Install two new shims (12) between barrel (13) and fuel pump (4).Tighten three nuts (11) and install fuel test line (9) on delivery valve holder (10).

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c. High-speed Fuel Delivery Test

NOTEMaintain 21 psi (145 kPa) calibration fluid pressure throughoutthis task.

1. Set test stand (4) to measure fuel delivery at 1,000 strokes.

2. Set fuel pump (1) to 1,050 rpm.NOTE

If needed, increase aneroid air pressure to obtain correct racktravel.

3. Move control lever (3) to obtain rack travel of 0.360-0.480 in. (9.14-12.19 mm).

4. Take fuel draw and check fuel delivery. Correct fuel delivery is 0.891-0.928 in.3 (14.6-15.2 cm3).5. Allowable reading spread is 0.037 in.3 (0.6 cm3).

d. Low-speed Fuel Delivery Test


1. Reduce fuel pump (1) to 300 rpm.2. Set control rack travel between 0.308-0.316 in. (7.8-8.0 mm).

3. Take fuel draw and check fuel delivery. Correct fuel delivery 0.079-0.134 in.3 (1.3-2.2 cm3)4. Allowable reading spread is 0.030 in3 (0.5 cm3).

e. Rated Speed Test

1. Install protractor (2) on control lever (3).2. Position control lever (3) between 42-50°

3. Increase rpm of fuel pump (1) until control rack travel of 0.464 in. (11.78 mm) is obtained.4. Fuel pump (1) rpm should be between 1,090-1,100.5. Increase rpm of fuel pump (1) to 1,185-1,215.6. Check control rack travel. Correct control rack travel should be 0.016 in (0.40 mm).7. Position control lever (3) between 10-18°.8. Adjust fuel pump (1) to 300 rpm.

9. Check control rack travel. Correct control rack travel should be 0.312 in. (7.9 mm).

10. Decrease fuel pump (1) to 100 rpm.

11. Check control rack travel. Correct control rack travel should be 0.372 in. (9.45 mm).12. Increase rpm of fuel pump (1) to 300. Check control rack travel. Correct control rack travel should

be 0.308-0.316 in. (7.82-8.03 mm).

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5-32. FUEL INJECTION PUMP PRETEST (Contd) I

f. Full Load Delivery

1. Apply 131 psi (903 kPa) of air pressure to manifold pressure compensator (2).2. Adjust fuel pump (1) to 1,050 rpm.3. Position control lever (3) in full load position.4. Take fuel draw and check delivery quantity. Correct fuel delivery quantity should be 8.90-9.28 in.3

(145.8-152.1 cm3).5. Allowable reading spread is 0.366 in.3 (5.998 cm3).6. Close air supply source to manifold pressure compensator (2).

g. Manifold Pressure Compensator Test

1. Set fuel pump (1) to 500 rpm and position control rack (5) at 0.038-0.039 in. (0.97-0.99 mm) controlrack travel.

2. Apply 44 psi (303 kPa) of air pressure to manifold pressure compensator (2) and observe controlrack travel. Correct control rack travel is 0.432-0.436 in. (10.97-11.07 mm).

3. Increased air pressure to 75 psi (517 kPa) and observe control rack travel. Correct control racktravel is 0.476-0.488 in. (12.09-12.39 mm).

4. Increase air pressure to 131 psi (903 kPa) and observe control rack travel. Correct control racktravel is 0.504-0.508 in. (12.80-12.90 mm).

5. Close air supply source to manifold pressure compensator (2).

h. Start Cut Out Test

1. Set fuel pump (1) to 240 rpm and run fuel pump (1) at this speed for approximately one minute.2. Move throttle lever (4) to full load position and measure control rack travel. Control rack travel

should be no more than 0.084 in. (2.13 mm).

i. Fuel Delivery Test

1.2.3.

4.5.

6.

7.

8.

Apply 131 psi (903 kPa) of air pressure to manifold compensator (2).Adjust fuel pump (1) to 700 rpm.Set test stand to measure fuel delivery at 1,000 strokes.

Check fuel delivery quantity. Correct fuel delivery quantity should be 8.73-9.21 in.3 (143-150.9 cm3).

Check fuel spread. Correct fuel spread should be 0.427 in. (6.99 cm).

Decrease fuel pump rpm to 500.

Check fuel delivery quantity. Correct fuel delivery quantity is 4.64-5.00 in.3 (76.0-81.9 cm3).

Close air supply source to manifold pressure compensator (2).

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j. Fuel Breakaway Test

1. Move control lever (3) to full load position.2. Gradually increase rpm of fuel pump (1) until control rack (6) moves 0.004 in. (0.1 mm) towards

shut off.

3. Adjust fuel pump (1) to 1,090-1,100 rpm.4. Move control lever (3) to full load position and observe control rack travel. Correct control rack

travel should be 0.464 in. (11.79 mm).

k. Starting Fuel Delivery Test

1. Set fuel pump (1) to 100 rpm.

2. Set test stand (5) to measure calibration fluid at 1,000 strokes.3. Position throttle lever (4) to full load position and observe control rack (6) travel. Correct control

rack travel should be 0.076-0.084 in. (1.93-2.13 mm).4. Check fuel delivery quantity. Correct fuel delivery quantity is 12.94-13.91 in.3 (212-227.9 cm3).

l. Low Idle Fuel Delivery Test

1. Set fuel pump (1) to 300 rpm.2. Position control lever (3) against low idle stopscrew (2) and take a fuel draw.

3. Observe control rack travel. Correct control rack travel is 0.308-0.316 in. (7.82-8.03 mm).

4. With test stand (5) set at 1,000 strokes, check fuel delivery quantity. Correct fuel delivery quantityshould be 0.824-1.373 in.3 (13.5-22.5 cm3).

5. Check fuel spread. Correct fuel spread should be 0.305 in.3 (4.90 cm3).

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FOLLOW-ON TASK: Remove fuel injection pump from test stand (para. 5-31).5-223

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5-33. MANIFOLD PRESSURE COMPENSATOR MAINTENANCE

THIS TASK COVERS:a. Removal d. Assemblyb. Disassembly e. Installationc. Cleaning and Inspection

INITIAL SETUP:

APPLICABLE MODELS REFERENCES (TM)M939A2 TM 9-2320-272-24P

TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1) Fuel injection pump pretest performed (para. 5-32).

MATERIALS/PARTSManifold pressure compensator maintenance

kit (Appendix D, Item 423)Silicone adhesive (Appendix C, Item 3)

a. Removal

1. Remove safety wire (1) from screw (24) and protective cap (2). Discard safety wire (1).

NOTE

2.

3.4.5.

6.

7.

8.

It may be necessary to cut a slot on breakoff screws for removal.

Remove breakoff screw (22), screw (24), lockwashers (21) and (23), protective cap (2), and pull-stop (3) from pull-stop cover (16). Discard breakoff screw (22) and lockwashers (21) and (23).Remove O-ring (4) from pull-stop (3). Discard O-ring (4).Remove nuts (20) and (19) from stop bolt (12).Remove three screws (18) and lockwashers (17) from pull-stop cover (16). Discard lockwashers (17).Remove breakoff screw (5), lockwasher (6), and pull-stop cover (16) from manifold pressurecompensator (7). Discard breakoff screw (5) and lockwasher (6).

Remove three screws (8), lockwashers (9), and washers (10) from manifold pressure compensator (7).Discard lockwashers (9).Remove breakoff screw (15), lockwasher (14), washer (13), and manifold pressure compensator (7)from governor cover (11). Discard breakoff screw (15) and lockwasher (14).

b. Disassembly

1. Remove cotter pin (28), washer (27), and lever (26) from stop bolt (12). Discard cotter pin (28).

2. Remove stop bolt (12) and spring (29) from manifold pressure compensator (7).3. Remove round nut (34), washer (33), washer plate (32), diaphragm (31), and washer plate (30) from

stop bolt (12). Discard diaphragm (31).4. Remove O-ring (25) from manifold pressure compensator (7). Discard O-ring (25).

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5-33. MANIFOLD PRESSURE COMPENSATOR MAINTENANCE (Contd)

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NOTERemove gasket sealant from mating surfaces.

1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.

d. Assembly

1. Install new O-ring (2) on manifold pressure compensator (1).

2. Install washer plate (8), new diaphragm (9), washer plate (10), and washer (11) on stop bolt (7) withround nut (12).

3. Install spring (6) and stop bolt (7) in manifold pressure compensator (1).4. Install lever (3) on stop bolt (7) with washer (4) and new cotter pin (5).

e. Installation

NOTEPerform step 1 to ensure manifold pressure compensator lever isengaged to rocker arm in governor cover.

1. Remove plug (24) from governor housing (23).2. Install manifold pressure compensator (1) on governor cover (22) with three washers (21), new

lockwashers (20), and screws (19).3. Install washer (25), new lockwasher (26), and new breakoff screw (27) on manifold pressure

compensator (1).

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NOTEApply silicone adhesive to mating surfaces of pull-stop cover andmanifold pressure compensator.

4. Install pull-stop cover (28) on manifold pressure compensator (1) with three new lockwashers (29)and screws (30).

5. Install new lockwasher (18) and new breakoff screw (17) on pull-stop cover (28).6. Install nuts (31) and (32) on stop bolt (7).7. Install new O-ring (16) on pull-stop (15).

8. Place pull-stop (15) in pull-stop cover (28).9. Install protective cap (33) on pull-stop cover (28) with new lockwashers (14) and (34), screw (13),

and new breakoff screw (35).10. Install plug (24) on governor housing (23).

NOTESafety wire will not be installed at this time. Safety wire will beinstalled after fuel pump is calibrated (para. 5-37).

FOLLOW-ON TASK: Calibrate fuel injection pump (para. 5-37).

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5-34. R.Q.V. GOVERNOR COVER MAINTENANCE

THIS TASK COVERS:a. Removal d. Assemblyb. Disassembly e. Adjustmentc. Cleaning and Inspection f. Installation

INITIAL SETUP:

APPLICABLE MODELS REFERENCES (TM)

M939A2

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Depth gauge (Appendix E, Item 81)

MATERIALS/PARTSR.Q.V. governor cover maintenance kit

(Appendix D, Item 562)Sealing compound (Appendix C, Item 61)

TM 9-2320-272-24P

EQUIPMENT CONDITIONManifold pressure compensator removed (para. 5-33).

a. Removal

1. Remove guide pin (8) and gasket (9) from governor cover (5). Discard gasket (9).

2. Remove five screws (10) from governor cover (5).

3. Remove two screws (12), lockwashers (13), governor stop (3), and two spacers (4) from governorcover (5). Discard lockwashers (13).

NOTEWhen removing governor cover, move governor lever back andforth.

4. Remove safety wire (6) from screws (7) and (11). Discard safety wire (6).

5. Remove screw (7), governor cover (5), and gasket (2) from governor housing (1). Discardgasket (2).

b. Disassembly

1. Remove two drive pins (25) from linkage lever (23) and shaft (19). Discard drive pins (25).2. Remove shaft (19) from governor cover (5).3. Remove screw (14), lockwasher (15), shim (16), template (17), and shim (18) from governor cover (5).

Discard lockwasher (15).4. Remove linkage lever (23) and intermediate plates (22) and (24) from governor cover (5).

5. Remove rocker arm (21) and spring (20) from governor cover (5).



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5-34. R.Q.V. GOVERNOR COVER MAINTENANCE (Contd)

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d. Assembly

1. Install spring (12)and rocker arm (13) in governor cover (3).2. Install intermediate plates (14) and (16) and linkage lever (15) in governor cover (3).3. Install shaft (11) in governor cover (3).4. Install shim (10), template (9), and shim (8) on governor cover (3) with new lockwasher (7) and

screw (6).5. Install two new drive pins (17) in linkage lever (15) and shaft (11).

e. Adjustment

1. Position control lever (4) in full load position so pilot (5) contacts bottom end of template slot (1).

2. Position new gasket (2) on governor cover (3).3. Place straightedge on governor cover (3). Using depth gauge, measure from straightedge to pilot (5).

Distance should be 0.098 in. (2.49 mm).NOTE

Perform steps 4 through 7 if measurement is incorrect.

4. Remove screw (6), lockwasher (7), shim (8), template (9), and shim (10) from governor cover (3).5. If distance is less than 0.098 in. (2.49 mm), use smaller shim (10).

6. If distance is more than 0.098 in. (2.49 mm), use larger shim (10).7. Install shim (10), template (9), and shim (8) on governor cover (3) with lockwasher (7) and screw (6).

f. Installation

NOTESafety wire will not be installed at this time. Safety wire will beinstalled after fuel pump is calibrated (para. 5-37).Linkage lever piston must fit into cylinder on lever located ingovernor housing.

1. Install new gasket (2) and governor cover (3) on governor housing (18) with five screws (24) andscrew (21).

2. Install governor stop (19) on governor cover (3) with two spacers (20), new lockwashers (25), andscrews (26).

NOTEApply sealing compound to male threads.

3. Install new gasket (23) and guide pin (22) in governor cover (3).

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FOLLOW-ON TASK: Install manifold pressure compensator (para. 5-33).

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5-35. R.Q.V. GOVERNOR HOUSING MAINTENANCE

THIS TASK COVERS:

a. Removalb. Disassemblyc. Cleaning and Inspection

d. Assemblye. Installationf. Adjustment

INITIAL SETUP:


TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Depth gauge (Appendix E, Item 81)Torque wrench (Appendix E, Item 144)

MATERIALS/PARTSR.Q.V. governor housing maintenance kit

(Appendix D, Item 561)


EQUIPMENT CONDITIONR.Q.V. governor cover removed (para. 5-34).

GENERAL SAFETY INSTRUCTIONSWear eye protection when removing or installingsprings under tension.

a. Removal

1.2.3.4.

5.

6.7.8.

9.10.

11.12.

13.14.

15.

Remove retaining pin (12) from link pin (10). Discard retaining pin (12).Remove link pin (10), slider (15), and lever (11) from link fork (9).Remove retaining pin (5) and link fork (9) from connection plate (3). Discard retaining pin (5).

Bend tab washer (19) away from two nuts (20).Remove nut (20). tab washer (19), nut (20), coupling pin (8), and washer (7) from flyweightassembly (6). Discard tab washer (19).Remove bearing pin (16) from guide bushing (17).Bend two tab washers (13) away from screws (14).Remove two screws (14), tab washers (13), and guide bushing (17) from flyweight assembly (6).Discard tab washers (13).

Remove round nut (18) from camshaft (4) and governor flyweight assembly (6).Remove governor flyweight assembly (6) from camshaft (4).

Remove capsule (21) and four rubber buffers (22) from driver (24). Discard rubber buffers (22).Remove shim (23) and driver (24) from camshaft (4).

NOTEScrews in steps 13 and 14 are torx head.

Remove four screws (28) and holding brackets (27) from governor housing (2).Remove two screws (26) from governor housing (2).

Remove two screws (25), governor housing (2), and gasket (29) from fuel pump housing (1). Discardgasket (29).

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5-35. R.Q.V. GOVERNOR HOUSING MAINTENANCE (Contd)

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b. Disassembly

NOTERelieve governor flyweight spring tension when performing step 1.

1. Press down on outer spring seat (3) and remove round nut (2) from threaded pin (9).

WARNING

Eye protection must be worn when removing springs undertension. Failure to do so may result in injury to personnel.

2. Remove outer spring seat (3), springs (4), (5), and (6), shim (7), and lower spring seat (8) fromgovernor flyweight assembly (12).

3. Remove shims (1) and (13) from governor flyweight assembly (12).


1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Inspect two governor flyweights (11) for nicks and scratches. If either flyweight (11) is nicked or

scratched, replace governor flyweight assembly (12).

4. Inspect bell crank levers (10) for noticeable wear. Replace governor flyweight assembly (12) if eitherbell crank lever (10) is worn.

5. Inspect bearing pin (14) for scratches, scoring, nicks, and wear. Replace bearing pin (14) ifscratched, scored, nicked, or worn.

6. Inspect guide bushing (15) for wear, scratches, or scores. Replace guide bushing (15) if worn,scratched, or scored.

d. Assembly

1. Install shims (13) and (1) in governor flyweight assembly (12).

WARNING

Eye protection must be worn when installing springs. Failure todo so may result in injury to personnel.

2. Install lower spring seat (8), shim (7), and springs (6), (5), and (4) in governor flyweightassembly (12).

3. Install outer spring seat (3) on spring (4).

4. Install round nut (2) on threaded pin (9).

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e. Installation

1.

2.3.4.

5.

6.

7.

8.

9.

10.

11.12.

13.

14.

Install new gasket (6) and governor housing (5) on fuel pump housing (7) with two screws (1) andscrews (2).Install four holding brackets (3) and screws (4) on governor housing (5).Place shim (28) in driver (29) and install driver (29) on camshaft (9).Install capsule (26) and four new rubber buffers (27) in back side of governor flyweightassembly (11).Install governor flyweight assembly (11) on driver (29).

Install round nut (23) on camshaft (9). Tighten round nut (23) 30-35 lb-ft (41-47 N·m).CAUTION

Failure to obtain proper axial play may cause damage to fuelpump.

Check governor flyweight assembly (11) for axial play:a. Normal range is 0.002-0.004 in. (0.05-0.1 mm).b. If axial play is less than 0.002 in. (0.05 mm), replace shim (28) with larger shim (28).

c. If axial play is more than 0.004 in. (0.1 mm), replace shim (28) with smaller shim (28).

d. When axial play is correctly adjusted, it is possible to turn governor flyweight assembly (11)without governor flyweight assembly (11) sticking.

NOTEDo not bend tab washer until fuel pump is calibrated (para. 5-37).

Install guide bushing (22) on flyweight assembly (11) with two new tab washers (18) and screws (19).Tighten screws (19) 53-71 lb-in. (6-8 N·m).Place bearing pin (21) in guide bushing (22).

NOTEAdjust nuts to allow end play of 0.04-0.12 in. (1.0-3.0 mm).

Insert coupling pin (13) through washer (12), governor flyweight assembly (11), and bearing pin (21)and install nut (25), new tab washer (24), and nut (25) on coupling pin (13). Tighten nuts (25)53-71 lb-in. (6-8 N·m).

Install slider (20) on bearing pin (21).Install lever (16) on slider (20).

Install link fork (14) on connection plate (8) with new retaining pin (10).

Install lever (16) on link fork (14) with link pin (15) and new retaining pin (17).

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f. Adjustment

1.

2.3.4.5.

6.7.

8.

9.10.

11.

12.

13.

14.15.16.

NOTEDistance is obtained by the measured distance plus the thicknessof straightedge minus half the thickness of slider.

Place straightedge on governor housing (1). Using depth gauge, measure distance between slider (2)and straightedge. Distance should be 1.39-1.40 in. (35.3-35.6 mm).

NOTEPerform steps 2 through 15 if measurement is incorrect.

Remove retaining pin (7) from link pin (6).Remove link pin (6). slider (2), and lever (8) from link fork (5) and bearing pin (11).Remove retaining pin (4) and link fork (5) from connection plate (3).Remove nut (14), tab washer (15), nut (14), coupling pin (9), and washer (10) from governorflyweight assembly (16).Remove bearing pin (11) from guide bushing (13).

If slider measurement was less than 1.39 in. (35.3 mm), turn adjusting screw (12) in bearing pin (11)clockwise.If slider measurement was more than 1.40 in. (35.6 mm), turn adjusting screw (12) in bearingpin (11) counterclockwise.Place bearing pin (11) in guide bushing (13).Install washer (10) on coupling pin (9) and insert coupling pin (9) through governor flyweightassembly (16) and bearing pin (11) and secure with nut (14), tab washer (15), and nut (14) oncoupling pin (9). Tighten nuts (14) 53-71 lb-in. (6-8 N·m).Bend tab washer (15) on nuts (14).

Install slider (2) on bearing pin (11).Install lever (8) on slider (2).

Install link fork (5) on connection plate (3) with retaining pin (4).Install lever (8) on link fork (5) with link pin (6) and retaining pin (7).Check distance between slider (2) and straightedge (step 1).

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FOLLOW-ON TASK: Install R.Q.V. governor cover (5-34).

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5-36. FUEL INJECTION PUMP MAINTENANCE

THIS TASK COVERS:

a. Camshaft Removalb. Tappet and Plunger Removalc. Barrel and Control Rack Removald. Cleaning and Inspectione. Leakage Test

f. Delivery Valve and Barrel Installationg. Plunger and Control Rack Installationh. Tappet and Spring Installationi. Camshaft Installation

INITIAL SETUP:


SPECIAL TOOLSTwo separation tubes (Appendix E, Item 119)Side plug puller (Appendix E, Item 111)Three tappet holders (Appendix E, Item 134)Tappet spring compressor (Appendix E, Item 135)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 144)Arbor press

MATERIALS/PARTSFuel injection pump repair kit (Appendix D,

Item 137)Fuel injection pump maintenance kit

(Appendix D, Item 136)

MATERIALS/PARTS (Contd)Sealing compound (Appendix C, Item 61)GAA grease (Appendix C, Item 28)Drycleaning solvent (Appendix C, Item 71)Lubricating oil (Appendix C, Item 50)


EQUIPMENT CONDITIONR.Q.V. governor housing removed (para. 5-35).

GENERAL SAFETY INSTRUCTIONSDiesel fuel is flammable. Do not perform this tasknear open flames.Keep fire extinguisher nearby when usingdrycleaning solvent.Drycleaning solvent is flammable and toxic. Donot use near open flame.

a. Camshaft Removal

WARNING

Diesel fuel is flammable. Do not perform fuel system procedurenear open flame. Injury to personnel may result.Drycleaning solvent is flammable and toxic. Do not use nearopen flame and always have a fire extinguisher nearby whensolvents are used. Use only in well-ventilated places, wearprotective clothing, and dispose of cleaning rags in approvedcontainer. Failure to do this may result in injury or death topersonnel and/or damage to equipment.

CAUTION

Improper cleaning methods and use of unauthorized cleaningsolvents can damage equipment.

1. Clean exterior of fuel pump housing (10) with drycleaning solvent.2. Using side plug puller, remove three side plugs (7) from fuel pump housing (10). Discard side plugs (7).3. Remove three spacer blocks (8) from side holes (9).

CAUTION

Keep cylinder parts together for replacement in their originalcylinder. Failure to do so may result in damage to fuel pump.

4. Remove six nuts (4), lockwashers (3), spacer rings (2), and locking tabs (1) from studs (5) and deliveryvalve holders (13). Discard lockwashers (3).

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5-36. FUEL INJECTION PUMP MAINTENANCE (Contd)

NOTEPerform step 5 to aid in insertion of tappet holder.

5. Loosen twelve barrel flange nuts (12) and remove twelve shims (6) from between barrel (11) andfuel pump housing (10).

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6.7.

8.9.

10.

11.

12.

13.

14. Remove camshaft (16), with bearing (23) and bearing shell (20), from governor end of fuel pumphousing (1).

15. Remove four screws (5), lockwashers (4), end plate (3), and gasket (2) from fuel pump housing (1).Discard gasket (2) and lockwashers (4).

16. Remove O-ring (6) and oil seal (7) from end plate (3). Discard O-ring (6) and oil seal (7).17. Remove O-ring (8) from fuel pump housing (1). Discard O-ring (8).

Reverse position of fuel pump housing (1) and mount in vise.Remove six screws (9), holding brackets (19), cover (18), and seal ring (17) from fuel pumphousing (1). Discard seal ring (17).

NOTECylinder number one is located at drive end of fuel pump.

Rotate camshaft (16) until cylinder number one is at Top Dead Center (TDC).Turn knurled handle (14) on tappet holder (15) fully counterclockwise.Apply GM grease to ramp (12) and guide (11) on tappet holder (15).

NOTETappet holder will insert only part way in when lifting tappetnumber one off camshaft.

Hold tappet holder (15) with ramp (12) up and insert tappet holder (15) into side hole (10) of fuelpump housing (1).

NOTEPressure must be maintained on handle of tappet holder toprevent tappet holder from popping out.When all six tappets are lifted off the camshaft, camshaft willrotate with little resistance.

Rotate camshaft (16) until cylinder number two is at TDC and push tappet holder (15) until taperededge (13) on tappet holder (15) contacts fuel pump housing (1).

NOTERepeat steps 8 through 12 to install remaining two tappet holders.

Remove two screws (21) and seal rings (22) from fuel pump housing (1). Discard seal rings (22).CAUTION

If arbor press is used, care should be taken to prevent damage tocontrol rack guide pin.

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b. Tappet and Plunger Removal

1.

2.

3.4.

5.6.7.

8.

9.

10.

11.

12.

NOTECamshaft must be removed to perform this task.

Position fuel pump housing (14) bottom side up in vise.NOTE

l Cylinder number one is located at drive end of fuel pump.

l Step 2 covers the removal of tappet holder from cylinders oneand two. Remaining tappet holders are removed the same.

Install spring compressor clamp (1) on governor side of fuel pump hosing (14) with two washers (2)and screws (3).Place spring compressor adapter (6) on shaft (5).Position shaft (5) and adapter (6) on the first two tappets (7).

Position lever (4) on spring compressor clamp (1) and shaft (5).Depress lever (4), compressing both tappets (7).Turn knurled knob (11) on tappet holder (10) fully clockwise and apply GAA grease to ramp (12) andguide (9) on tappet holder (10).While both tappets (7) are compressed, remove tappet holder (10) from side hole (8) of cylinders oneand two.

NOTERepeat steps 2 through 8 until all tappet holders are removed.

Remove two screws (3), washers (2), spring compressor clamp (1), lever (4), shaft (5), and adapter (6)from fuel pump housing (14).

CAUTION

Keep cylinder parts together for replacement in their originalcylinder. Failure to do so may result in damage to fuel pump.

Remove six tappets (7), lower spring seats (15), plungers (16), and springs (20) from fuel pumphousing (14).Position control rack (13) to align control sleeve ball (17) with notch (21) on fuel pump housing (14).

Remove six upper control sleeves (18) and upper spring seats (19) from fuel pump housing (14).

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c . Barrel and Control Rack Removal

1. Position fuel pump housing (5) top side up in vise.2. Loosen six delivery valve holders (1) from barrels (9).3. Remove twelve barrel flange nuts (2), lockwashers (3), and spacer rings (4) from fuel pump

housing (5). Discard lockwashers (3).4. Remove six barrels (9) from fuel pump housing (5).

5. Remove six O-rings (8) from barrels (9). Discard O-rings (8).6. Remove six retainers (6) and capsules (7) from barrels (9). Discard retainers (6).

7. Remove six delivery valve holders (1), washers (12), springs (11), and delivery valves (10) frombarrels (9).

8. Remove six O-rings (13) from delivery valve holders (1). Discard O-rings (13).

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9.10.

11.12.

Remove two screws (19) and retaining plate (20) from control rack (18) and fuel pump housing (5).

Remove control rack (18), spring retainer (17), spring (16), and washer (15) from fuel pumphousing (5).

NOTEPerform step 11 if control rod is damaged.

Remove control rod (14) from fuel pump housing (5).Remove fuel pump housing (5) from vise.

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1.2.

3.

4.

5.6.

7.8.9.

10.

11.12.13.

For general cleaning instructions, refer to para. 2-14.Inspect plunger (1) for scratches and scoring. Replace plunger (1) and barrel (5) if plunger (1) isscratched or scored.

Inspect delivery valve (4) for wear and scoring. If worn or scored, replace delivery valve (4).

NOTEReplace all camshaft bearings if camshaft requires replacement.

Inspect camshaft (7) for scratches and gouged lobes (6). If lobes (6) are scratched or gouged, replacecamshaft (7).

NOTEPerform steps 5 through 7 if camshaft and endplate bearingsrequire replacement.

Press roller bearing (2) from end plate (3).Remove nut (10) and lockwasher (9) from camshaft (7). Discard lockwasher (9).

Press bearing (8) from camshaft (7).Inspect tappets (11) for wear or scratches. If worn or scratched, replace tappets (11).Inspect six spacers (14) in fuel pump housing (13) for burrs, scratches, and nicks. If burred,scratched or nicked, replace spacer (14).

NOTEPerform steps 10 through 12 if spacer requires replacement.

Bend edges of spacers (14) in towards center of port (12).

Drive six spacers (14) out through top of fuel pump housing (13). Discard spacers (14).Remove six O-rings (15) from fuel pump housing (13). Discard O-rings (15).For general inspection instructions, refer to para. 2-15.

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e. Leakage Test

1.2.

3.4.

5.

6.

7.

8.

9.10.11.

12.13.14.

CAUTION

Plungers and barrels are matched sets. Do not interchange partsor damage to fuel pump may result.

NOTEBarrels must be installed (subtask f) to perform this task.

Position fuel pump housing (1) bottom side up in vise.Install six plungers (4) in mating barrels (7). Position plunger (4) so groove (5) on plunger (4) pointsaway from rack.Install plunger retainer tubes (2) on fuel pump housing (1) with two bottom cover screws (3).Remove fuel pump housing (1) from vise.

Install screw plug (8) in fuel gallery outlet (9).

Connect air hose to fuel gallery inlet (6).Submerge fuel pump housing (1) in clean test oil bath and pressurize fuel pump housing (1) to75 psi (517 kPa).Check for bubbles at top and bottom of fuel pump housing (1). Any bubbles, other than smallbubbles from inside of plunger retainer tubes (2), indicate a leak.If leaks are present, replace fuel pump housing (1).Disconnect air hose from gallery inlet (6).Remove screw plug (8) from gallery outlet (9).

Remove two bottom cover screws (3) and plunger retainer tubes (2) from fuel pump housing (1).Remove six plungers (4) from barrels (7).Remove fuel pump housing (1) from vise.

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f. Delivery Valve and Barrel Installation

1.

2.

3.4.

5.

6.7.8.

9.10.

11.12.

13.

NOTEl The following subtask covers installation of one barrel. Remaining

barrels are installed the same.l Coat all parts with oil before installation.

l Coat all O-rings with GAA grease.NOTE

Perform steps 1 and 2 if spacer was removed.Install new O-ring (13) in fuel pump housing (11).Using arbor press, press new spacer (14) through top of fuel pump housing (11).Position fuel pump housing (11) top side up in vise.

Install new O-ring (22) on delivery valve holder (1).

Install delivery valve (191, spring (20), washer (21), and delivery valve holder (1) in correspondingbarrel (18).Install new O-ring (17) on barrel (18).Install capsule (16) on barrel (18) with new retainer (15).Position barrel (18) in corresponding cylinder (12) and install with two spacer rings (8), newlockwashers (7), and barrel flange nuts (6). Tighten nuts (6) finger tight.

Place two shims (9) between barrel (18) and fuel pump housing (11).Tighten nuts (6) 15-20 lb-ft (20-27 N•m).

Tighten delivery valve holder (1) 35-45 lb-ft (47-61 N•m).Install locking tab (5), spacer ring (4), new lockwasher (2), and nut (3) on stud (10) and deliveryvalve holder (1). Tighten nut (3) 15-20 lb-ft (20-27 N•m).Remove fuel pump housing (11) from vise.

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g. Plunger and Control Rack Installation

NOTEPerform step 1 if control rod was removed.

1. Install new control rod (1) on fuel pump housing (9).2. Install washer (2), spring (3), and cap (4) on control rod (1).3. Install control rack (5) and retaining plate (6) on fuel pump housing (9) with two screws (7).4. Mount fuel pump housing (9) bottom side up in vise.

5. Position control rack (5) so guide slits (8) align with notch (18) on fuel pump housing (9).NOTE

Control sleeve balls engage guide slit on control rack.

6. Install six upper control sleeves (15) into mating barrels (16).7. After all control sleeves (15) are installed, move control rack (5) back and forth to ensure control

sleeves (14) move freely.CAUTION

Once correct alignment is obtained, secure control rack in thisposition until tappets are installed. Failure to do so may result indamage to control sleeves.

8. Position control rack (5) so guide slits (8) face adjusting groove (17) on barrel (16).9. Coat six upper spring seats (14) with GAA grease and position on control sleeves (15).

10. Install six springs (13) on mating control sleeves (15).CAUTION

Notch on plungers must align exactly with groove on barrel. Ifalignment is not obtained, damage to fuel pump may result.

11. Install six plungers (12) into mating barrels (16) so notched mark (11) on plunger base pointstoward adjusting groove (17) on barrel (16).

12. Install six lower spring seats (10) on plungers (12) and rotate lower spring seats (10) 90°.

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h. Tappet and Spring Installation

1.

2.

3.4.5.

6.7.

8.

9.

10.

CAUTION

When performing step 1, ensure flats on tappet align with recesson the lower spring seat. Failure to do so may result in damage tofuel pump housing.

NOTEThis task covers installation of two tappets for cylinders numberone and two. Remaining tappets are installed the same.

Install two tappets (1) in mating cylinders.Install spring compressor clamp (3) on governor side of fuel pump housing (2) with two washers (4)and screws (5).Place spring compressor adapter (8) on shaft (7).Position shaft (7) and adapter (8) on the first two tappets (1).Position lever (6) on spring compressor clamp (3) and shaft (7).

Depress lever (6), compressing both tappets (1).Turn knurled knob (12) on tappet holder (13) fully counterclockwise and apply GM grease toramp (11) and guide (10) on tappet holder (13).While both tappets (1) are compressed, insert tappet holder (13) into side hole (9) of cylinders oneand two.

NOTERepeat steps 1 through 8 until all tappets and tappet holders areinstalled.

Remove two screws (5), washers, (4), spring compressor clamp (3), lever (6), shaft (7), andcompressor adapter (8) from fuel pump housing (2).

Remove fuel pump housing (2) from vise.

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i. Camshaft Installation

1.

2.

3.

4.

5.6.

7.

8.

9.

Position fuel pump housing (1) bottom side up in vise.

NOTEPerform step 2 if roller bearing was removed.

Press roller bearing (8) on end plate (3).

Install new O-ring (6) and oil seal (7) on end plate (3).

Position new gasket (2) and end plate (3) on fuel pump housing (1). Ensure oil return holes arelocated at top of fuel pump housing (1).Install end plate (3) on fuel pump housing (1) with four new lockwashers (4) and screws (5).If bearing (16) was removed, press bearing (16) on camshaft (10) and secure bearing (16) oncamshaft (10) with new lockwasher (15) and nut (14).Install new O-ring (9) on fuel pump housing (1).

CAUTION

When installing camshaft into fuel pump housing, tap only oncamshaft outer nut. Failure to do so may result in damage to fuelpump.

Insert camshaft (10) and bearing shell (13) into fuel pump housing (1) through governor end of fuelpump housing (1).Install bearing shell (13) on fuel pump housing (1) with two new seal rings (12) and screws (11).

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NOTESteps 10 through 12 cover removal of one tappet holder. Remainingtappet holders are removed the same.

10. Turn knurled handle (7) on tappet holder (8) fully clockwise.NOTE

Cylinder number one is located at drive end of fuel injection pump.

11. Hold tappet holder (8) and rotate camshaft (9) until cylinder number one is at TDC and pull tappetholder (8) from side hole (6).

12. Rotate camshaft (9) until cylinder number two is at TDC and remove tappet holder (8) from sidehole (6).

13. Install new seal ring (4) and bottom cover (3) on fuel pump housing (5) with six holdingbrackets (1) and screws (2).

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14. Install three spacer blocks (11) in fuel pump housing (5) through side holes (12).

15. Apply sealing compound to new side plugs (10) and install side plugs (10) in fuel pump housing (5).

16. Remove fuel pump housing (5) from vise.

FOLLOW-ON TASK: Install R.Q.V. governor housing (para. 5-35).

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5-37. FUEL INJECTION PUMP CALIBRATION

THIS TASK COVERS:a. Prestroke and Back Travelb. Cylinder Phasing (Timing)c. Lock Timingd. High-speed Fuel Delivery Teste. Low-speed Fuel Delivery Testf. Bated Speed Testg. Full Load Delivery

h. Manifold Pressure Compensator Testi. Fuel Delivery Testj. Fuel Breakaway Testk. Starting Fuel Delivery Testl. Low Idle Fuel Delivery Testm. External Stop Setting

INITIAL SETUP:


SPECIAL TOOLSPlunger lift device (Appendix E, Item 98)Rack extension (Appendix E, Item 112)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Dial indicator (Appendix E, Item 36)

MATERIALS/PARTSTwo copper washers (Appendix D, Item 44)Two break off screws (Appendix D, Item 19)Two lockwashers (Appendix D, Item 397)Copper washer (Appendix D, Item 42)Two breakoff screws (Appendix D, Item 20)Four lockwashers (Appendix D, Item 398)Lubricating oil (Appendix C, Item 50)Safety wire (Appendix C, Item 79)

REFERENCES (TM)TM 9-2320-272-24PTM 9-4910-778-14&P

EQUIPMENT CONDITIONl Fuel injection pump repaired (para. 5-36).l Fuel injection pump mounted to test stand

(para. 5-31).

NOTERefer to TM 9-4910-778-14&P for operation of fuel injection pumptest stand, DFP 156.

1.

2.

3.4.

5.6.7.8.

9.

Mount dial indicator (2) and rack travel indicator holder (1) on drive end of fuel pump (5).NOTE

Cylinder number one is located at drive end of fuel injection pump.Install plunger lift device (8) on fuel pump (5) with finger of lifting device (8) resting on top oftappet located in cylinder number one.

Mount dial indicator (7) on lifting device (8) and zero dial indicator (7).Pull control lever (6) to full load position and using dial indicator shaft (3), push control rack (4) allthe way back.

Preload dial indicator (2) giving control rack (4) 0.004 in. (0.1 mm) of preload travel.Manually rotate test stand driveshaft (9) until a reading is observed on dial indicator (7).Manually reverse rotation test stand driveshaft (9) until dial indicator (7) reads zero.Manually rotate test stand driveshaft (9) clockwise and take prestroke measurement from dialindicator (7). Correct prestroke measurement should be 0.120-0.128 in. (3.05-3.25 mm).

If correct prestroke measurement is not obtained, perform steps 10 through 13.

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5-37. FUEL INJECTION PUMP CALIBRATION (Contd)

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10.11.

Steps 10 through 13 pertain to adjusting one cylinder. Remainingfive cylinders are adjusted the same.

Remove fuel test line (12) from delivery valve holder (11).Loosen three nuts (10) and remove two shims (2) between barrel (9) and fuel pump (8). Discardshims (2).

CAUTION

Adjusting shims of the same thickness must be used on both sidesof barrel. Failure to do so may result in inaccurate prestrokemeasurement.

NOTE

12.13.

Refer to TM 9-2320-272-24P to select shims.Install two new shims (2) between barrel (9) and fuel pump (8).Tighten three nuts (10) and install fuel test line (12) on delivery valve holder (11).

NOTE

14.

15.

Cylinder number one is located at drive end of fuel pump.

Close all bleedoff valves (1) except for cylinder number one.Apply 435-464 psi (2,999-3,199 kPa) of calibration fluid pressure.

NOTE

16.

Ensure a steady stream of calibration fluid flows from number onebleedoff valve. If not, increase calibration fluid pressure until asteady stream of calibration fluid is obtained.

Manually rotate test stand driveshaft (7) in correct fuel pump (8) rotation, until calibration fluidstarts to drip from bleedoff valve (1).

17. Check prestroke measurement. Correct measurement should be 0.360-0.480 in. (9.14-12.19 mm).

18. Remove dial indicator (3) and plunger lift device (4) from fuel pump (8).

19. Install new copper washer (6) and plug (5) on fuel pump (8).

NOTE

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b. Cylinder Phasing (Timing)

NOTEl When phasing (timing) cylinders, test stand calibration fluid

pressure must be set at 435-464 psi (2,999-3,199 kPa).l When performing this task, correct prestroke measurement

must be obtained for cylinder number one. Refer to task a.

1. Zero test stand protractor (6) on drive end of test stand (5).2. Close all bleedoff valves (2) except for cylinder number five.

NOTEWhen bleedoff valve is opened, a stream of calibration fluid willflow from bleedoff valve. If not, increase fluid pressure until astream of calibration fluid is obtained.

3. Open bleedoff valve (2) on test nozzle (3) for cylinder number five.4. Manually rotate test stand driveshaft (7) in correct rotation of fuel pump (4) until calibration fluid

starts to drip from number five bleedoff valve (2).5. Observe reading on test stand protractor (6). Correct reading is 60°.

NOTEl Following fuel pump firing order 1-5-3-6-2-4, repeat steps 2

through 5 until remaining cylinders are phased (timed).l For each cylinder phased (timed), test stand protractor should

increase in 60° intervals.

6. If 60° intervals are not obtained, adjust shims under barrel (1) (task a).7. If any adjustments are made to bring the remaining cylinders to specification, repeat steps 1

through 6 to ensure all cylinders are phased (timed) to specifications.

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c. Lock Timing

NOTEFuel pump must be phased (timed) before performing this task.Refer to task b.

1. Remove access plug (7), washer (8), and timing pin (3) from timing plate (2).

2. Rotate test stand drive (9) until number one cylinder is at port closure.3. Rotate test stand drive (9) in correct pump rotation 8° from cylinder one port closure.

4. Timing tooth (11) should be aligned with timing pin access hole (10).NOTE

Perform steps 5 through 11 if drive pointer is not aligned withtiming pin access hole.

5. Remove governor cover from governor housing (para. 5-34).

6. Remove two breakoff screws (6), lockwashers (5), washers (4), and timing plate (2) from governorhousing (1). Discard lockwashers (5) and breakoff screws (6).

7. Remove governor flyweight and driver from fuel pump (para. 5-35).8. Install timing plate (2) on governor housing (1) with two washers (4), new lockwashers (5), and new

breakoff screws (6).NOTE

l Align driver so timing tooth aligns with timing pin access hole.

l Timing plate can be adjusted up or down for final alignment.

9. Install governor flyweight and driver on fuel pump (para. 5-35).

10. Install timing pin (3) in timing plate (2) with slot of timing pin (3) facing timing tooth (11).11. Install washer (8) and access plug (7) on timing plate (2).12. Tighten breakoff screws (6).13. Install governor cover on governor housing (para. 5-34).

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d. High-speed Fuel Delivery Test

1.2.

3.

4.

5.6.

7.

8.

9.

10.11.

12.

13.

14.

15.

16.

NOTEl Maintain 22 psi (152 kPa) calibration fluid pressure throughout

this task.l Close all bleedoff valves.

Set test stand (12) to measure fuel delivery at 1,000 strokes.Remove plug (4) from top of governor housing (5) and pour two pints of lubricating oil in governorhousing (5).

Remove plug (13) and washer (10) from fuel pump (9).

Install new copper washer (10), adapter (11), new copper washer (10), and plug (13) on fuel pump (9).

Connect return line (1) to adapter (11).Adjust fuel pump (9) to 1,050 rpm.

NOTEAdjust aneroid air pressure to help obtain correct rack travel.

Adjust control lever (8) to obtain rack travel of 0.360-0.480 in. (9.14-12.19 mm).NOTE

Perform steps 8 and 9 if correct rack travel is not obtained.

Remove breakoff screw (19), screw (21), two lockwashers (18), protective cap (17), and stop (16) frommanifold pressure compensator (6). Discard breakoff screw (19) and two lockwashers (18).Turn nuts (15) and (14) counterclockwise to increase rack travel; or clockwise to decrease racktravel.Position control lever (8) to full load and take fuel draw.Check fuel delivery. Correct fuel delivery should be 0.891-0.928 in.3 (14.6-15.2 cm3).

Allowable spread reading is 0.037 in.3 (0.6 cm3).NOTE

l Perform step 13 if fuel delivery deviates from specifications.

l Step 13 pertains to one cylinder only.Loosen three nuts (2) and rotate barrel (3) clockwise to increase fuel delivery; counterclockwise todecrease fuel delivery.

Repeat step 13 for remaining cylinders.Install stop (16) and protective cap (17) on manifold pressure compensator (6) with two newlockwashers (18), screw (21), and new breakoff screw (20).

Install new safety wire (22) on screw (21) and protective cap (17).

e. Low-speed Fuel Delivery Test


1. Reduce fuel pump (9) to 300 rpm.

2. Set control rack travel at 0.308-0.316 in. (7.8-8.0 mm).

3. Check fuel delivery. Correct fuel delivery should be 0.079-0.134 in.3 (1.3-2.2 cm3).

4. Allowable spread reading is 0.030 in.3 (0.5 cm3).

5. If low-speed fuel delivery deviates from specifications given, adjust low idle stopscrew (7) untilcorrect fuel delivery is obtained.

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5-37 FUEL INJECTION PUMP CALIBRATION (Contd)

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f. Rated Speed Test

1.

2.

3.

4.5.

6. Increase rpm of fuel pump (2) until a rack travel of 0.464 in. (11.79 mm) is obtained.7. Rpm of fuel pump (2) should be at 1,090-1,100 rpm.8. Adjust rpm of fuel pump (2) until rack travel of 0.312 in. (7.9 mm) is obtained.9. Rpm of fuel pump (2) should be at 300 rpm.

10. Decrease rpm of fuel pump (2) to 100 rpm. Rack travel should be 0.372 in. (9.45 mm).

Loosen nut (7) on low idle stopscrew (5) and turn low idle stopscrew (5) until flush with governorcover (6).Position control level (4) until dial indicator (1) on drive end of fuel pump (2) reads zero.

Slowly move control lever (4) towards full load, until dial indicator (1) receives reading.

Set protractor (3) at zero.Position control lever (4) to read 42-50° on protractor (3) by adjusting low idle stop-screw (5).

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NOTEPerform steps 11 through 17 if proper control rack travel was notobtained.

11. Remove safety wire (10) from governor housing (8).12. Remove plug (9) from governor housing (8), giving access to governor springs.

NOTERepeat steps 13 and 14 until both governor springs are adjusted.

13. If control rack travel reading is too low at a given speed, increase flyweight spring tension byturning round nut (11) clockwise.

14. If control rack travel reading is too high at a given speed, decrease flyweight spring tension byturning round nut (11) counterclockwise.

15. Recheck control rack travel. If control rack travel is incorrect, repeat step 13 or 14. If rack travel iscorrect, proceed to step 16.

16. Install plug (9) on governor housing (5).

17. Install new safety wire (10) on governor housing (8).

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g. Full Load Delivery

1.2.3.4.5.6.

7.8.9.

10.11.

12.

13.14.

15.

Apply 13.05 psi (90 kPa) of air to manifold pressure compensator (6).Adjust fuel pump (7) to 1,050 rpm.Set fuel test stand to measure fuel delivery at 1,000 strokes.Reduce fuel pump (7) to 700 rpm.Position control lever (8) to full load position.Take fuel draw and observe delivery quantity. Correct delivery quantity should be 9.1-9.2 in.3

(149.1-150.8 cm3).

Check spread reading. Correct spread reading is 0.366 in.3 (6.00 cm3).Close air supply source to manifold pressure compensator (6).Reduce fuel pump (7) to 500 rpm.Position control lever (8) to full load position.Take fuel draw and observe delivery quantity. Correct delivery quantity is 4.8-4.9 in.3

(78.7-80.3 cm3).NOTE

Perform steps 12 through 14 if fuel delivery quantity deviatesfrom specifications.

Remove breakoff screw (10), screw (1), two lockwashers (3), protective cap (4), and stop (5) frommanifold pressure compensator (6). Discard two lockwashers (3) and breakoff screw (10).Turn nut (9) clockwise to increase fuel delivery; counterclockwise to decrease fuel delivery.Install stop (5) and protective cap (4) on manifold pressure compensator (6) with two new lock-washers (3), new breakoff screw (11), and screw (1).

Install new safety wire (2) on screw (1) and protective cap (4).

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h. Manifold Pressure Compensator Test

1. Set fuel pump (7) to 500 rpm and position control rack (12) between 0.041-0.042 in.(1.040-1.060 mm) rack travel.

2. Apply 3.26 psi (22.5 kPa) of air pressure to manifold pressure compensator (6) and observe controlrack (12) travel. Correct control rack (12) travel is 0.429-04.36 in. (11.90-12.30 mm).

3. Increase air pressure of manifold pressure compensator (6) to 6.53 psi (45.0 kPa) and observecontrol rack (12) travel. Correct control rack (12) travel is 0.468-0.484 in. (11.90-12.30 mm).

NOTEPerform steps 5 through 8 if control rack travel deviates fromspecifications.

4. Remove plug (14) from top of governor housing (13).

5. If control rack (12) travel is less than required specifications, turn screw (15) clockwise.6. If control rack (12) travel is more than required specifications, turn screw (15) counterclockwise.

7 . Recheck control rack (12) travel. If control rack (12) travel is incorrect, repeat step 6 or 7. If controlrack (12) travel is correct, proceed to step 9.

8 . Install plug (14) on governor housing (13).

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i. Fuel Delivery Test

1.2.3.4.

5.

6.

7.8.9.

Apply 13.1 psi (90.3 kPa) to manifold pressure compensator (2).Adjust fuel pump (1) to 700 rpm.Set test stand to measure fuel delivery at 1,000 strokes.Set control lever (3) to full load position.

Check fuel delivery quantity. Correct fuel delivery quantity should be 8.73-9.21 in.3

(143.0-151.0 cm3).Check fuel spread. Fuel spread should be 0.427 in.3 (7.0 cm3).

Decrease fuel pump speed (1) to 500 rpm.Check fuel delivery quantity. Correct fuel delivery quantity is 5.61-5.74 in.3 (92.0-94.0 cm3).Adjust fuel delivery quantity by turning each barrel assembly (4) counterclockwise or clockwiseuntil correct fuel delivery quantity is obtained.

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5-37. FUEL INJECTION PUMP CALIBRATION. (Contd)

j. Fuel Breakaway Test

1. Move control lever (3) to full load position.

2. Gradually increase rpm of fuel pump (1) rpm until control rack (5) moves 0.004 in. (0.1 mm)towards shutoff.

3. Rpm of fuel pump (1) should be 1,090-1,100 rpm. Perform step 5 if correct rpm is not obtained.4. Move control lever (3) to full load position and observe travel of control rack. Correct control rack

travel should be 0.464 in. (11.79 mm).

5. If breakaway is not as specified rpm, adjust high-speed stopscrew (7) until correct breakaway isobtained.

k. Starting Fuel Delivery Test

1. Set fuel pump (1) to 100 rpm.2. Set test stand to measure calibration fluid at 1,000 strokes.3. Position throttle lever (6) so control rack (5) is at full load 0.827 in. (21 mm).4. Take fuel draw and check delivery quantity. Correct delivery quantity is 12.94-13.91 in.3

(212.0-228.0 cm3).

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l. Low Idle Fuel Delivery Test

1. Set fuel pump (1) to 300 rpm.2. Position control lever (6) against idle stopscrew (5) and take a fuel draw.3. Observe control rack travel. Correct control rack travel should be 0.308-0.316 in. (7.80-8.03 mm).4. With test stand set at 1,000 strokes, take fuel draw and check delivery quantity. Correct delivery

quantity is 0.824-1.373 in.3 (13.5-22.5 cm3).5. If fuel delivery deviates from specifications, adjust idle stopscrew (5) until correct fuel delivery is

obtained.

m. External Stop Setting

Perform this task so control rack has a 0.039 in. (1 mm) preload.Failure to do so may result in damage to fuel pump.

1. Loosen adjusting nut (3) on throttle stopscrew (4).2. Position throttle lever (2) against throttle stopscrew (4).3. Adjust throttle stopscrew (4) until 0.039 in. (1 mm) preload is observed on dial indicator (7) and

tighten adjusting nut (3).

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FOLLOW-ON TASK: Remove fuel injection pump from test stand (para. 5-31).

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Section III. TRANSMISSION MAINTENANCE

5-38. TRANSMISSION MAINTENANCE INDEX

PARA. TITLE PAGENO. NO.

5-39.5-40.5-41.5-42.5-43.

5-44.

5-45.5-46.5-47.5-48.5-49.5-50.5-51.

5-52.5-53.5-54.5-55.5-56.5-57.

5-58.

5-59. Transmission Housing Maintenance

5-60. Transmission Oil Pressure Testing5-61. Transmission Modulator Maintenance5-62. Transmission Converter Stall Test

General Maintenance Instructions

Transmission Mounting to Holding FixtureTransmission Torque Converter MaintenanceTransmission Oil Pan and Filter MaintenanceModulate Lockup Valve, Low Trimmer Valve, and Low ShiftValve Replacement

Transmission Control Valve ReplacementTransmission Manual Selector Shaft ReplacementTransmission Oil Pump and Front Support MaintenanceForward Clutch MaintenanceFourth Clutch MaintenanceThird Clutch MaintenanceCenter Support MaintenanceGear Unit and Main Shaft Maintenance

Second Clutch MaintenanceFirst Clutch MaintenanceTransmission Governor ReplacementRear Cover and Low Planetary Carrier MaintenanceLow Clutch Removal and ClearanceAdapter Housing and First Clutch Piston MaintenanceAdapter Housing, Low Clutch, Low Planetary Carrier, and RearCover Installation

5-281

5-2825-2865-300

5-304

5-3065-3085-3105-3225-3325-3385-3405-348

5-3545-3585-3625-3645-3745-378

5-382

5-3845-3865-3945-396

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5-39. GENERAL MAINTENANCE INSTRUCTIONS

WARNING

l Drycleaning solvent is flammable and will not be used nearopen flame. Use only in well-ventilated places. Failure to doso may result in injury to personnel.

l Compressed air source will not exceed 30 psi (20 kPa). Whencleaning with compressed air, eyeshields must be worn. Failureto wear eyeshields may result in injury to personnel.

l When converter pump hub, front support (including groundsleeve), or oil pump is defective, install wide oil pump kit. Thiskit converts an early model transmission (P/N 6885292) into alate model transmission (P/N 23040127). Failure to simultaneouslyinstall all parts of kit may cause damage to transmission duringassembly or may cause transmission malfunction.

NOTEl Refer to para. 2-14 for cleaning all transmission components.l Make sure location markings are not removed when cleaning.

l All transmission parts must be lubricated with cleanOE/HDO-10 lubricating oil before assembly.

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5-40. TRANSMISSION MOUNTING TO HOLDING FIXTURE

THIS TASK COVERSa. Installation b. Removal

INITIAL SETUP:

APPLICABLE MODELSAll

SPECIAL TOOLSHolding fixture adapter set (Appendix E,

Item 64)Holding fixture (Appendix E, Item 63)Holding fixture base (Appendix E, Item 65)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Lifting deviceChain

MATERIALS/PARTSGasket (Appendix D, Item 224)


EQUIPMENT CONDITIONTransmission removed from vehicle (para. 4-71) ortransmission removed from engine (para. 4-72).


GENERAL SAFETY INSTRUCTIONSl All personnel must stand clear during lifting

operations.l Do not remove hoist chain from transmission until

transmission is stable. Injury to personnel mayresult.

a. Installation

1. Remove six screws (4), power takeoff cover (3), and gasket (2) from transmission (1). Discardgasket (2).

2. Install holding plate (6) and holding fixture (5) on right side of transmission (1) with six washers (7)and screws (8).

NOTETransmission may be mounted on any overhaul stand or holdingfixture. However, the front, rear, and bottom of transmission mustbe freely accessible for removal and installation of components.

3. Install holding fixture base (10) on overhaul stand (11) with four screws (14), washers (13), andnuts (12).

WARNING

l All personnel must stand clear during lifting operations.A snapped cable, or swinging or shifting load, may causeinjury to personnel.

l Do not remove hoist chain from transmission until transmissionis stable on holding fixture base, or injury to personnel mayresult.

4. Using lifting device and chain, lift transmission (1) and holding fixture (5) into position and installin holding fixture base (10) with pin (15) and setscrew (9).

5. Remove chain and lifting device from transmission (1)

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5-40. TRANSMISSION MOUNTING TO HOLDING FIXTURE (Contd)

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b. Removal

1.2.3.

4.

Attach lifting device and chain to transmission (1).Remove pin (7) from holding fixture base (6) and loosen setscrew (5).Support transmission (1) with chain and lifting device and remove transmission (1) and holdingfixture (8) from holding fixture base (6).Remove six screws (4), washers (3), holding fixture (8), and holding plate (2) from transmission (1)and holding fixture (8).

5. Install new gasket (9) and power takeoff cover (10) on transmission (1) with six screws (11).6. Remove lifting device and chain from transmission (1).

WARNING

All personnel must stand clear during lifting operations.A snapped cable, or swinging or shifting load, may causeinjury to personnel.


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FOLLOW-ON TASK: Install transmission on engine (para. 4-72) or install transmission in vehicle(para. 4-71).

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5-41. TRANSMISSION TORQUE CONVERTER MAINTENANCE

THIS TASK COVERSa. Removal d. Assemblyb. Disassembly e. Installationc. Cleaning and Inspection

INITIAL SETUP:


SPECIAL TOOLSBearing puller set (Appendix E. Item 105)Drive handle (Appendix E, Item 38)Bearing replacer (Appendix E, Item 15)Bushing replacer (Appendix E, Item 25)

TOOLSArbor pressGeneral mechanic’s tool kit (Appendix E, Item 1)Vernier caliper (Appendix E, Item 159)Torque wrench (Appendix E, Item 144)

MATERIALS/PARTSConverter pump seal ring (Appendix D, Item 636)Flywheel seal ring (Appendix D, Item 638)Hook-type seal (Appendix D, Item 637)Piston seal ring (Appendix D, Item 520)Pump hub gasket (Appendix D, Item 225)Six lockstraps (Appendix D, Item 342)Thirty self-locking screws (Appendix D, Item 648)Lubricating oil (Appendix C, Item 49)Oil-soluble grease (Appendix C, Item 53)


EQUIPMENT CONDITIONTransmission mounted to holding fixture (para. 5-40).


a. Removal

NOTEAssistant will help with steps 1 and 2.

1. Remove four nuts (1), washers (2), and screws (4) from converter retaining strap (3) andtransmission (7).

CAUTION

Torque converter must be pulled straight out of transmission andnot moved from side to side. Side movement will damage hook-type seal ring on torque converter pump hub.

2. Pull converter retaining strap (3) with torque converter (5) straight out of transmission (7).

3. Remove two screws (6) and converter retaining strap (3) from torque converter (5).

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5-41. TRANSMISSION TORQUE CONVERTER MAINTENANCE (Contd)

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b. Disassembly

1.

2.

3.4.5.

6.

7.

8.

9.10.

11.12.

13.14.15.

16.

17.18.

NOTEHook-type seal ring used on early models.

Remove hook-type seal ring (12) from torque converter pump hub (11). Discard hook-typeseal ring (12).

NOTEl Have drainage container ready to catch transmission oil.

l Assistant will help with step 2.Remove thirty self-locking screws (13) and washers (14) from converter pump (7) and converterflywheel (1), and drain transmission oil. Discard self-locking screws (13).Separate converter pump (7) from converter flywheel (1).Remove seal ring (6) from converter pump (7). Discard seal ring (6).Remove roller thrust bearing (2) and bearing race (3) from converter flywheel (1) or converterpump (7).Bend corners of six lockstraps (5) away from twelve screws (4) and remove twelve screws (4), sixlockstraps (5), and retainer (15) from converter pump (7). Discard lockstraps (5).Remove torque converter pump hub (11) and gasket (10) from converter pump (7). Discardgasket (10).

NOTEl Early model transmission converter pump has a snapring and

roller bearing inside front bore. Late model converter pump hubhas no snapring or roller bearing, but does have a nose withflats.

l Perform step 8 for early model transmission.

Using bearing puller set, remove snapring (8) and roller bearing (9) from torque converter pumphub (11).Remove stator (26) from converter turbine (25).Turn roller race (31) clockwise and lift off stator (26).

Remove ten rollers (27) and springs (28) from stator (26).Remove thrust bearing (30) and race (29) from stator (26).

NOTEConverter turbine must be pulled straight off flywheel, or it willbind.

Remove converter turbine (25) from converter flywheel (1).Using bearing puller, remove ball bearing (22) and spacer (23) from turbine hub (24).Remove lockup clutch plate (19), backplate (20), and two backplate keys (21) from converterflywheel (1).

NOTEScribe mark on converter flywheel and lockup clutch piston forinstallation.

Place converter flywheel (1) upright and remove lockup clutch piston (17). If lockup clutchpiston (17) sticks, tap flywheel (1) lightly with soft-faced hammer.Remove piston seal ring (18) from piston (17). Discard piston seal ring (18).Remove flywheel seal ring (16) from converter flywheel (1). Discard flywheel seal ring (16).

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1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Inspect lockup clutch disc (1) for burned surfaces. If burned, discard lockup clutch disc (1).4. Measure thickness of lockup clutch disk (1). If thickness is less than 0.190 in. (4.32 mm), discard

lockup clutch disc (1).

5. Measure thickness of thrust bearing race (2). If thickness is less than 0.029 in. (0.74 mm), discardthrust bearing race (2).

6. Inspect roller race (4) for scoring. If scored, discard roller race (4).NOTE

Step 7 refers to early model pump hub.7. Inspect pump hub (3) for cracks, breaks, burred flats, and scored seal surface and bearing bore. If

damage is more than minor scoring, discard pump hub (3).NOTE

Step 8 refers to late model pump hub.

8. Inspect pump hub (3) for cracks, breaks, burred flats, and scored seal surface and bushing journal.If damage is more than minor scoring, discard pump hub (3).

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d. Assembly

NOTEl Steps 2 and 14 obtain measurements to select proper spacer

thickness. These measuring steps are treated as assembly steps.l Steps 2 and 3 are performed only if new bearing is being

installed.1. Install ball bearing (5) in flywheel bore (7). Ensure ball bearing (5) seats against shoulder of

flywheel bore (7).

2. Place straightedge (6) across flywheel bore (7) and measure the distance from inner race of ballbearing (5) to straightedge (6). Record this measurement for use in step 14d.

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3.4.5.6.

7.

8.

9.

Remove ball bearing (8) from flywheel (1).Apply lubricating oil to new flywheel seal ring (2) and install on flywheel (1).Apply lubricating oil to new piston seal ring (4) and install on lockup clutch piston (3).Align previously scribed marks on lockup clutch piston (3) and install, cupped side first, onflywheel (1).Soak lockup clutch plate (5) in clean lubricating oil for at least two minutes. Install lockup clutchplate (5) on clutch piston (3).Position two backplate keys (7) in flywheel (1) recesses.

NOTEBackplate and backplate keys must be level for the next step.

Install lockup clutch backplate (6).a. Position lockup clutch backplate (6) in flywheel (1), engaging notch in lockup clutch backplate (6)

with two backplate keys (7).CAUTION

If backplate is not approximately level with the key, the lockupclutch piston is not properly engaged with the drive pins in theflywheel. Rotate the piston until it drops into place on the pins.Damage to backplate will result if piston is not engaged properly.

NOTEPerform step b only if backplate is not level with the keys.

b. Rotate piston (3) until pin holes and flywheel (1) pins are aligned.

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10.

11.

12.

13.

14.

15.

NOTELate model transmission does not have roller bearing or snap-ring in front bore of torque converter pump hub.Perform step 10 if bearing is to be installed in early modeltransmission.

Using an arbor press and bearing remover/installer, press roller bearing (16) in torque converterpump hub (18) and install with snapring (15).

CAUTION

Identify transmission model. Late model converter pump hub haslonger nose and has 1 in. (25.4 mm) long flats that fit into oilpump (para. 5-39). Do not intermix parts from early and latemodel transmissions. Damage to transmission will result.

Install new gasket (17) and torque converter pump hub (18) on converter pump (14) withretainer (13), six new lockstraps (12), and twelve screws (11). Tighten screws (11) 33-40 lb-ft(45-54 N•m). Bend comers of lockstraps (12) against head of each screw (11).

Install bearing race (10) and roller thrust bearing (9) in converter pump (14).

Install bearing race (25), thrust bearing (26), and freewheel roller race (27) in stator (24) and placestator (24) and converter turbine (21) in converter pump (14). Center stator (24) and converterturbine (21) carefully.

NOTEStep 14 is performed only if new bearing was installed in step 1.

Select spacer (23) size:

a. Place gauge blocks (22) of equal height on edge of converter pump (14) as shownb. Place straightedge (19) across gauge blocks (22) and measure distance from straightedge (19) to

shoulder (20) adjacent to hub of turbine (21). Record this measurement.c. Subtract measurement obtained in step 14b. from gauge block height. Record this measurement.d. Subtract measurement obtained in step 14c. from measurement obtained in step 2. Using this

measurement, refer to table 5-11 to select correct size spacer (23).Table 5-11. Torque Converter Spacer Sizes.

Measurements Spacer0.018-0.032 in. (0.457-0.813 mm) Gold

0.032-0.044 in. (0.813-1.117 mm) Silver

0.044-0.062 in. (1.117-1.575 mm) Plain0.062-0.077 in. (1.575-1.956 mm) Black0.077-0.096 in. (1.956-2.438 mm) Copper

Remove converter turbine (21) from converter pump (14).

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16.

17.18.19.20.

21.

22.

23.

24.25.26.

27.

28.

Install spacer (3) on converter turbine hub (4).

Install ball bearing (2) on converter turbine hub (4) until seated against spacer (3).Install converter turbine (5) in flywheel (1).Remove stator (6) from converter pump (12).Remove freewheel roller race (10) and thrust bearing (9) from stator (6).

NOTEOne of three different types of roller springs will be present inearly stators as shown. Either the later or latest type shouldbe used, but all springs must be of the same type.The latest type roller springs are installed in a differentmanner. The old tab may be either up or down.Oil-soluble grease will hold springs and rollers in place.

Pack stator cam pockets (17) with oil-soluble grease and install springs (8) and rollers (7) in statorcam pockets (17).Apply a small amount of oil-soluble grease to thrust bearing (9) and position thrust bearing (9) tofreewheel roller race (10).

Position freewheel roller race (10) and thrust bearing (9) in stator (6) and turn clockwise untilseated in stator (6).Position stator (6) on converter turbine (5).Apply lubricating oil to new seal ring (11) and install on converter pump (12).Install converter pump (12) on flywheel (1) with thirty new self-locking washers (16) and new self-locking screws (15). Tighten screws (15) 41-49 lb-ft (56-66 N•m).

NOTEHook-type seal ring used on early models.

Install new hook-type seal ring (13) on torque converter pump hub (14).

Install converter retaining strap (19) on torque converter (18) with two screws (20).

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1. Tilt transmission (7) to horizontal position, with oil pan (6) facing downward.CAUTION

Torque converter must be installed straight on transmission andnot moved from side to side. Side movement will damage hook-type seal ring on turbine shaft.


2. Install torque converter (5) in transmission (7). Ensure seal ring is properly positioned. Torqueconverter (5) may be rotated until flat sides of pump hub engage flats in oil pump drive gear.

3. Install converter retaining strap (3) on transmission (7) with four screws (4), washers (2), and nuts (1).

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FOLLOW-ON TASK: Remove transmission from holding fixture (para. 5-40).

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5-42. TRANSMISSION OIL PAN AND FILTER MAINTENANCE

THIS TASK COVERS:

a. Removal c . Ins ta l la t ionb. Cleaning and Inspection

INITIAL SETUP:

APPLICABLE MODELS REFERENCES (TM)All TM 9-2320-272-24P

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 146)

MATERIALS/PARTSO-ring (Appendix D, Item 429)Transmission oil filter (Appendix D, Item 699)Gasket (Appendix D, Item 159)

EQUIPMENT CONDITIONTransmission torque converter removed (para. 5-41).


1. Remove twenty-one screws (l), oil pan (2), and gasket (3) from transmission (4). Discardgasket (3).

2. Rotate transmission (4) in stand until oil pan (2) mounting surface is horizontal and facing upward.3. Remove oil filter screw (6), oil filter (7), and filter suction tube (8) from transmission (4).4. Remove filter suction tube (8) from oil filter (7). Discard oil filter (7).5. Remove O-ring (9) from filter suction tube (8). Discard O-ring (9).

1. For general cleaning instructions, refer to para. 2-14.

2. For general inspection instructions, refer to para. 2-15.3. Inspect oil pan (2) for cracks. If cracked, replace oil pan (2).

NOTENew oil pan has a plug in left side fill port.If oil pan is defective, remove plug if present.

4. Remove oil plug (5). Retain for installation in new oil pan (2).

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5-42. TRANSMISSION OIL PAN AND FILTER MAINTENANCE (Contd)

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1.2.

3.

4.

5.

6.

7.

NOTEKeep oil pan mounting surface in horizontal position and facingupward.Filter suction tube ends are interchangeable.

Insert one end of filter suction tube (3) into new transmission oil filter assembly (2).Install new O-ring (4) onto opposite end of filter suction tube (3).

Position new transmission oil filter assembly (2) on transmission (6). Ensure filter suctiontube (3) is inserted into oil input port (5).Install new transmission oil filter assembly (2) on transmission (6) with screw (1). Tightenscrew (1) 10-15 lb-ft (14-20 N•m).

CAUTION

Do not use silicone-type gasket sealing compound when installinggasket, because oil leakage may result. Oil or light grease coatingmay be used to hold gasket in position during installation.

Position new oil pan gasket (10) against housing of transmission (6) and align with holes oftransmission (6).

Position transmission oil pan (7) against oil pan gasket (10) and install with twenty-one screws (9).Tighten screws (9) finger-tight.Tighten twenty-one screws (9) 10-15 lb-ft (14-20 N•m) following torque sequence shown.

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NOTEDue to gasket compression, torque values will be lost and screwsmust be retightened.

8. Tighten twenty-one screws (9) 15-20 lb-ft (20-27 N•m) following torque sequence shown to achievefinal torque.

NOTEPerform step 9 only if new oil pan was installed.

9. Install plug (8) in oil pan (7). Ensure plug (8) is installed opposite hole for dipstick.

FOLLOW-ON TASK: Install transmission torque converter (para. 5-41).

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5-43. MODULATE LOCKUP VALVE, LOW TRIMMER VALVE, AND LOW SHIFT VALVEREPLACEMENT

THIS TASK COVERS:

a. Removal b . Ins ta l la t ion

INITIAL SETUP:



TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1) Transmission oil pan and filter removed (para. 5-42).Torque wrench (Appendix E, Item 146)


1. Remove three screws (5) and modulated lockup valve (6) from oil transfer plate (4).2. Remove six screws (1) and low trimmer valve (2) from low shift valve (3).3. Remove two screws (7) and low shift valve (3) from oil transfer plate (4).

NOTEKeep oil pan mounting surface in horizontal position and facingupward.

1. Install low shift valve (3) on oil transfer plate (4) with two screws (7). Finger-tighten screws (7).2. Install low trimmer valve (2) on low shift valve (3) with six screws (1). Tighten screws (1) and (7)

9-11 lb-ft (12-15 N•m) in sequence shown.

3. Install modulated lockup valve (6) on oil transfer plate (4) with three screws (5). Tighten screws (5)9-11 lb-ft (12-15 N•m) in sequence shown.

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5-43. MODULATE LOCKUP VALVE, LOW TRIMMER VALVE, AND LOW SHIFT VALVEREPLACEMENT (Contd)

FOLLOW-ON TASK: Install transmission oil pan and filter (para. 5-42).

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5-44. TRANSMISSION CONTROL VALVE REPLACEMENT

THIS TASK COVERS:


INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDITIONAll Low shift valve, low trimmer valve, and modulate

TOOLSlockup valve removed (para. 5-43).

General mechanic’s tool kit (Appendix E, Item 1) SPECIAL ENVIRONMENTAL CONDITIONSTorque wrench (Appendix E, Item 146) Work area clean and free from blowing dirt and


dust.

NOTESeparate and tag screws for installation.

1. Remove screw (4) and detent spring and roller (5) from control valve (2).2. Remove three screws (3) from control valve (2).3. Remove screw (1) from control valve (2).4. Remove fifteen screws (6) from control valve (2).

CAUTION

Do not tilt control valve to allow selector valve to drop out.Selector valve may be damaged.

Remove items as an assembly and do not separate. Loose partsinside will fall free, resulting in damage to control valve.

5. Remove control valve (2), separator plate (7), and oil transfer plate (8) from transmission (11).

b. Installation

CAUTION

Do not tilt control valve to allow selector valve to drop out.Damage to selector valve may result.

1. Position oil transfer plate (8), separator plate (7), and control valve (2) on transmission (11) so pinon detent lever (10) aligns with slot on selector valve (9).

2. Install control valve (2) on transmission (11) with fifteen screws (6). Finger-tighten screws (6).3. Install control valve (2) with three screws (3). Finger-tighten screws (3).4. Install control valve (2) with screw (1). Finger-tighten screw (1).5. Position detent spring and roller (5) on control valve (2) with roller in notch of detent lever (10), and

install with screw (4).

6. Tighten twenty screws (1), (3), (4), and (6) 9-11 lb-ft (12-15 N•m) in sequence shown.

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5-44. TRANSMISSION CONTROL VALVE REPLACEMENT (Contd)

FOLLOW-ON TASK: Install low shift valve, low trimmer valve, and modulate lockup valve (para. 5-43).

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5-45. TRANSMISSION MANUAL SELECTOR SHAFT REPLACEMENT

THIS TASK COVERS:


INITIAL SETUP:


TOOLS

EQUIPMENT CONDITIONTransmission selector shaft oil seal removed

(para. 4-76).Transmission control valve removed (para. 5-44).

General mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 146) SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TM)Work area clean and free from blowing dirt anddust.

TM 9-2320-272-24P

1. Remove shaft retainer pin (3) from transmission housing (4).2. Remove nut (2) and detent lever (1) from transmission manual selector shaft (5).3. Remove transmission manual selector shaft (5) from transmission housing (4).

1. Tilt transmission housing (4) to horizontal position with the bottom facing upward.

2. Install manual selector shaft (5) and detent lever (1) on transmission housing (4) with nut (2).Tighten nut 15-20 lb-ft (20-27 N•m).

3. Secure manual selector shaft (5) in transmission housing (4) with shaft retainer pin (3).

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5-45. TRANSMISSION MANUAL SELECTOR SHAFT REPLACEMENT (Contd)

FOLLOW-ON TASK: Install transmission selector shaft oil seal (para. 4-76).Install transmission control valve (para. 5-44).

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5-46. TRANSMISSION OIL PUMP AND FRONT SUPPORT MAINTENANCE

THIS TASK COVERS:

a . Remova l d. Assemblyb. Disassembly e . Ins ta l la t ionc. Cleaning and Inspection

INITIAL SETUP:


SPECIAL TOOLSTwo guide pins (Appendix E, Item 60)Front support lifter (Appendix E, Item 48)Bearing installer (Appendix E, Item 11)Driver handle (Appendix E, Item 38)Valve pin remover (Appendix E, Item 155)Slide hammer (Appendix E, Item 122)Main regulator and lockup spring compressor

(Appendix E, Item 129)Adapters (Appendix E, Item 2)Centering band (Appendix E, Item 90)Bushing replacer (Appendix E, Item 25)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Depth micrometer (Appendix E, Item 81)Torque wrench (Appendix E, Item 146)Arbor press

MATERIALS/PARTSOil seal (Appendix D, Item 502)Two self-locking screws (Appendix D, Item 649)Twelve self-locking screws (Appendix D, Item 650)Two hook-type seal rings (Appendix D, Item 638)Twelve washers (Appendix D, Item 713)Oil pump seal ring (Appendix D, Item 226)Oil pump gasket (Appendix D, Item 227)Valve guide pin (Appendix D, Item 705)Lubricating oil (Appendix C, Item 47)Oil-soluble grease (Appendix C, Item 53)Sealing compound (Appendix C, Item 62)


EQUIPMENT CONDITIONTransmission manual selector shaft removed(para. 5-45).


GENERAL SAFETY INSTRUCTIONSUse care when removing snaprings and retainingrings.

1. Position transmission (5) front upward.2. Remove twelve screws (2) and washers (1) connecting oil pump and front support (4) to

transmission (5). Discard washers (1).

3. Attach front support lifter to converter ground sleeve (3) on oil pump and front support (4).NOTE

Assistant will help with step 4.

4. Remove oil pump and front support (4) from transmission (5) by lifting straight up. Assistant maytap surface with a rubber hammer to ease removal.

5. Remove oil pump gasket (6). Discard oil pump gasket (6).

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5-46. TRANSMISSION OIL PUMP AND FRONT SUPPORT MAINTENANCE (Contd)

5-311

1.2.3.4.5.6.

7.

8.

9.

10.

11.12.

13.

Remove two hook-type seal rings (8) from oil pump (19) and front support (5). Discard seal rings (8).Remove bearing and race (7) from oil pump (19) and front support (5) or transmission.Remove oil pump seal ring (1) from oil pump (19) and front support (5). Discard oil pump seal ring (1).If replacement is necessary, remove needle bearing (6) from front support hub ground sleeve (9).Install valve pin remover tool on slide hammer on oil pump (19) and front support (5).Attach valve pin remover tool between coils of valve spring (3) and valve guide pin (2).


Remove valve guide pin (2), valve spring (3), and converter pressure regulator valve (4). Discardvalve guide pin (2). Tag valve spring (3) for installation.

WARNING

Regulator valve spring is under approximately 65 lb (29 kg)compression. Do not remove retaining snapring until compressoris in place, or regulator valve spring may fly out causing injury.

NOTEFor transmissions with serial numbers 21628 and higher, use twoadapters with spring compressor.

Attach main regulator and lockup spring compressor to front support (5) and tighten twoscrews (23) to relieve spring compression.

NOTEPerform steps 9 and 10 for transmissions with serial numbers21628 and higher.

Remove twelve self-locking screws (25) and two self-locking screws (24) and separate oil pump (19)from front support (5). Mark location for installation. Discard self-locking screws (24) and (25).

Remove two cross pins (26) from front support (5).NOTE

Perform step 11 for transmissions with serial numbers prior to21628.

Remove snaprings (10) and (11) from oil pump (19) and front support (5).Carefully remove and detach main regulator lockup spring compressor, valve stops (12) and (17),valve springs (13) and (16), regulator valve (15), and lockup valve (14) from front support (5). Marklocations for installation. Tag valve springs (13) and (16) for installation.

NOTEPerform step 13 for transmissions with serial numbers prior to21628.

Remove twelve self-locking screws (25) and two self-locking screws (24) connecting oil pump (19) tofront support (5). Separate oil pump (19) from front support (5). Mark location for installation anddiscard self-locking screws (25) and (24).


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TM 9-2320-272-24-4


NOTEDo not perform steps 14 and 15 unless relative movement isapparent between ground sleeve and front support.

14. If plug (22) is loose or damaged, remove plug (22) from front support (5).15. Remove oil pump gears (20) and (21) and oil pump body oil seal (18) from oil pump (19).

Discard body oil seal (18).

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1.2.

3.4.

5.6.

7.

8.

9.10.11.12.

CAUTION

Early model and late model converter pump hub, Front support seals,and oil pump are not interchangeable. Do not intermix parts fromearly and late transmissions. Damage to transmission will result.

For general cleaning instructions, refer to para. 2-14.For general inspection instructions, refer to para. 2-15.

Inspect oil pump gears (3) and (4) for broken teeth. Discard gears if broken.

Install oil pump gears (3) and (4) in pump body (2).

Place straightedge (1) across face of oil pump (2).Measure clearance between straightedge (1) and gear (4). If clearance is more than 0.0020 in.(0.051 mm), replace with thicker gear (4). Repeat steps 4 through 6.

NOTEPerform step 7 for late model transmissions only. Early modeltransmissions do not have bushing.

Measure inside diameter of bushing (5) on oil pump (2) at 5 o’clock position when viewed from thefront. Maximum wear limit is 2.257 in. (57.33 mm). Brass backing showing through is acceptable ifwear limit is not exceeded.Inspect bushing (5) on oil pump (2) for scoring. Replace bushing (5) if scoring can be felt. Useinstaller/remover tool and arbor press.Inspect bushing (5) on oil pump (2) for discoloration due to overheating. Replace if discolored.Inspect all springs for discoloration due to overheating. Discard if discolored.Inspect all springs for broken coils or coils distorted due to wear. Discard if broken or distorted.Using spring tester, inspect for serviceability by checking load when spring is compressed to thecorrect length. Discard spring if spring does not give the correct load (table 5-12).

SPRING

Main pressureregulator valve spring

Converter pressureregulator valve spring

COLOR

Green

Blue

Table 5-12. Spring Data.

FREE LENGTH COMPRESSED LENGTH

3.57 in. 2.01 in.(90.7 mm) (51.0 mm)

1.24 in. 1.05 in.(31.5 mm) (26.7 mm)

UNDER LOAD

70.6-76.6 lb(314-341 N)

33.1-40.5 lb(147-180 N)

Lockup valve spring Yellow 2.84 in. 1.46 in. 26.1-28.9 lb(72.1 mm) (37.1 mm) (116-129 N)

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5-315

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CAUTION

Oil seals for early and late model oil pumps are notinterchangeable (para. 5-39).

NOTECoat all internal parts, except oil pump, with lubricating oil

OE/HDO-10 prior to assembly.

Perform steps 1 through 3 only if gears and oil seal wereremoved.

1. Using oil-soluble grease, coat outside diameter of new oil pump seal ring (1)2. Install new oil pump seal ring (1) in oil pump body (2) 0.030-0.050 in. (1.76-1.27 mm) below outer

edge of bore. Install spring-loaded lip first. Use depth micrometer for measurement.3. Using oil-soluble grease, coat oil pump body seal (1) lip.4. Install oil pump gears (3) and (4).

NOTEFor transmissions with serial numbers 21628 and higher, use twoadapters with spring compressor.

5. Install regulator valve (11), lockup valve (9), valve springs (12) and (8), and valve stops (13) and (7) infront support (10) at location marked during disassembly.

6. Attach main regulator and lockup spring compressor to front support (10) and tighten screws (14)until snapring grooves or crosspin holes are visible in front of valve stops.

NOTEPerform step 7 for transmissions with serial numbers prior to21628.

7. Install snaprings (5) and (6) over valve stops (13) and (7). Tighten screws (14) until snapringgrooves are visible in front of valve stops (7) and (13).

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8.

9.

10.11.

12.

13.

14.

NOTEPerform step 8 for transmissions with serial numbers 21628 andhigher.

Install two cross pins (2) in pin holes of front support (1).

Detach and remove main regulator and spring compressor from front support (1).

NOTEPerform step 10 only if plug was previously removed.

Install plug (3) in front support (1).

Position oil pump (6) to front support (1) and align holes for screws (4) and (5). Install oil pump (6)to front support (1) with two new self-locking screws (4) positioned 180° apart. Finger-tightenscrews (4).

Install centering band around oil pump (6).Install oil pump (6) on front support (1) with remaining ten new self-locking screws (4) and twonew self-locking screws (5). Tighten screws (4) 17-20 lb-ft (23-27 N•m). Tighten screws (5) 36-42 lb-ft(23-27 N•m).Remove centering band from oil pump (6) to front support (1) and check separation line between oilpump (6) and front support (1). If mating point between oil pump (6) and front support (1) is notperfectly smooth by touch, loosen screws (4) and (5). Repeat steps 12 through 14.

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NOTEPerform step 15 only if needle bearing was previously removed.

15. Position needle bearing (8) on converter ground sleeve (9). Ensure numbered end of needlebearing (8) faces outward.

16. Using bearing installer and driver handle, press needle bearing (8) into converter groundsleeve (9) 1.240-1.260 in. (31.50-32.00 mm) below outer edge of bore.

NOTEPerform steps 17 and 18 only if converter pressure regulator valvewas previously removed.

17. Place valve spring (11) and converter pressure valve (10) on new valve guide pin (7).18. Press new valve guide pin (7) into front support (1) until new value guide pin (7) extends

1.16-1.20 in. (29.46-30.48 mm) above finished surface.NOTE

Two seal rings for front support hub are installed when oil pumpand front support are installed in transmission.

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1.

2.3.

4.

5.6.

7.

8.

CAUTION

Identify transmission model before assembly of oil pump and frontsupport. If early model converter hub was replaced with latemodel converter hub, a late model oil pump and front supportmust be installed, or transmission may be damaged duringassembly (para. 5-39).

NOTELate model oil pump is thicker than early model oil pump.Late model front support has a bushing and a thicker seal in oilpump hub. Early model oil pump hub has a thin seal and thetorque converter hub has a roller bearing.

Install bearing and race (2) on turbine shaft (3).NOTE

Guide pins maintain gasket alignment.Install two guide pins (5) and new oil pump gasket (1) into transmission (4).Apply oil-soluble grease sparingly to two new seal rings (10) to hold in place, and install sealrings (10) on hub (9) of oil pump (7) and front support (8).

Apply oil-soluble grease to new oil pump and ring coil, and install new oil pump seal ring (6) on oilpump (7) and front support (8).

Attach front support lifter to converter ground sleeve (12).Align front support holes (13) with corresponding holes in transmission (4), and carefully installfront support (8) in transmission (4) over guide pins (5).Remove two guide pins (5) and front support lifter from transmission (4).Install front support (8) on transmission (4) with twelve new rubber-covered washers (14) andscrews (11). Tighten screws (11) as follows:

a. Tighten alternately 180° apart. Tighten screws (11) 15 lb-ft (20 N•m).

b. Repeat tightening sequence 180° apart to achieve final torque. Tighten screws (11) 24-32 lb-ft(33-43 N•m).

5-320

TM 9-2320-272-24-4


FOLLOW-ON TASK: Install transmission manual selector shaft (para. 5-45).

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TM 9-2320-272-24-4

5-47. FORWARD CLUTCH MAINTENANCE

THIS TASK COVERS:

a. Removal d. Assemblyb. Disassembly e . Ins ta l la t ionc. Cleaning and Inspection

INITIAL SETUP:


SPECIAL TOOLSSpring compressor (Appendix E, Item 95)Forward clutch clearance gauge (Appendix E,

Item 46)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Spring tester (Appendix E, Item 131)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)Depth gauge (Appendix E, Item 81)Arbor press

MATERIALS/PARTSTwo turbine shaft seal rings (Appendix D,

Item 640)Turbine shaft seal ring (Appendix D, Item 639)Piston inner seal ring (Appendix D, Item 515)Piston outer seal ring (Appendix D, Item 516)Oil-soluble grease (Appendix C, Item 53)Lubricating oil (Appendix C, Item 47)


EQUIPMENT CONDITIONTransmission oil pump and front support removed(para. 5-46).


1. Lift forward clutch housing (9) and turbine shaft (1) straight out from transmission (5).

NOTEPerform step 2 for transmissions with three-piece bearing.

2. Remove bearing race (2), roller bearing (3), and bearing race (4) from turbine shaft (1).NOTE

Perform step 3 for transmissions with single-piece bearing assembly.3. Remove bearing assembly (6) from turbine shaft (1).

1. Remove seal ring (10) and two seal rings (11) from turbine shaft (1). Discard seal ring (10) and twoseal rings (11).

NOTESupport Power Takeoff (PTO) drive gear on arbor press for steps 2through 6.

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5-47. FORWARD CLUTCH MAINTENANCE (Contd)

2. Locate opening (missing spline) in forward clutch housing (9) nearest snapring (12) gap.

3. Press snapring (12) into groove in clutch housing (9) and insert one piece of shim stock (8) throughopening between snapring (12), Power Takeoff (PTO) gear (7), and teeth of clutch housing (9).

4. Repeat step 3, inserting remaining pieces of shim stock (8) into PTO gear approximately 5 in.(127 mm) apart.

5. Lift PTO gear (7) off clutch housing (9).6. Remove snapring (12) and shim stock (8) from clutch housing (9).

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7.8.

Remove snapring (6) from forward clutch housing (16).Remove fourth clutch drive hub (5) and forward clutch hub (4) from forward clutch housing (16).

NOTE

9.

Perform step 9 for transmission with three-piece bearing.

Remove bearing race (7), bearing (8), and bearing race (9) from forward clutch housing (16) orfourth clutch hub (5).

NOTEPerform step 10 for transmissions with single-piece bearingassembly.

10. Remove bearing assembly (3) from forward clutch housing (16).CAUTION

Keep all parts together. Intermixing forward clutch parts with anyother clutch pack will cause transmission damage.

NOTETag all clutch parts for reassembly.

11. Remove six clutch plates (1) and six clutch discs (2) from forward clutch housing (16).NOTE

12.

13.14.15.

16.17.

Use arbor press with compression tool for step 12.Position compressor tool on spring retainer (11) and place on arbor press.

Apply pressure on spring retainer (11) and remove snapring (10) from forward clutch housing (16).Remove compressor tool from spring retainer (11) and arbor press.Remove spring retainer (11), piston return spring (12), piston (13), and piston inner seal ring (15)from forward clutch housing (16). Discard piston inner seal ring (15).Remove piston outer seal ring (14) from piston (13). Discard piston outer seal ring (14).Remove retainer pin (20), valve plug (19), valve spring (18), and centrifugal valve (17) from forwardclutch housing (16).

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5-325

TM 9-2320-272-24-4


1.2.3.

4.

5.

6.

7.

8.

9.

10.

For general cleaning instructions, refer to para. 2-14.For general inspection instructions, refer to para. 2-15.Inspect turbine shaft and forward clutch housing (1) for scoring in area where seals contactturbine shaft (1). If scored, discard turbine shaft and forward clutch housing (1).

Inspect clutch plates (2) for burned surfaces. If burned, discard clutch plates (2).

Inspect clutch discs (3) for burned surfaces. If burned, discard clutch discs (3).Measure thickness of fourth clutch drive hub (4) at clutch disc (3) contact area. If thickness is lessthan 0.248 in. (6.30 mm), discard fourth clutch drive hub (4).Inspect valve spring (5) and piston return spring (6) for discoloration due to overheating. Ifdiscolored, discard.Inspect valve spring (5) and piston return spring (6) for broken coils or coils distorted due to wear. Ifbroken or distorted, discard.

Using spring tester, inspect valve spring (5) for serviceability.a. Compress valve spring (5) to 0.61 in. (15.5 mm) and check load (table 5-13).b. If valve spring (5) does not give load of 5.7-6.3 lb (25.3-28 N), discard.Using spring tester, inspect piston return spring (6) for serviceability.a. Compress piston return spring (6) to 1.28 in. (32.5 mm) (table 5-13).b. If piston return spring (6) does not give load of 158-178 lb (707-791 N), discard.


SPRING COLOR FREE LENGTH COMPRESSEDLENGTH UNDER LOAD

Valve spring

Piston returnspring

Green

None

0.76 in. 0.61 in. 5.7-6.3 lb(19.3 mm) (15.5 mm) (25.3-28 N)

3.22 in. 1.28 in. 158-178 lb(81.8 mm) (32.5 mm) (702-791 N)

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5-327

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1.

2.

3.

4.

5.

6.

7.8.

9.

10.

11.

12.13.

14.

15.

16.

17.

18.

5-328

NOTEIf new centrifugal valve is being installed, all components musthave same color code as old valve.

Install centrifugal valve (3) and valve spring (2) in forward clutch housing (16). Ensure pointed endof centrifugal valve (3) is installed first.Push valve plug (1) into forward clutch housing (16) and install with retainer pin (17). Retainer pin (17)must protrude 0.080-0.100 in. (2.03-2.54 mm) above front surface of forward clutch housing (16).Apply oil-soluble grease to new piston outer seal ring (12) and install new piston outer seal ring (12)on piston (10). Ensure piston outer seal ring (12) lips face toward oil pressure side of piston (10).Apply oil-soluble grease to new piston inner seal ring (15) and install new piston inner seal ring (15)on forward clutch housing (16) hub. Ensure piston inner seal ring (15) lips face toward oil pressureside of piston (10).Install piston (10) in forward clutch housing (16).

NOTESteps 6 through 12 obtain clutch running clearance.

Starting with clutch plate (5), alternately install six clutch plates (5) and six clutch discs (4) inforward clutch housing (16).Position fourth clutch drive hub (6) in forward clutch housing (16) and install with snapring (7).Measure clearance between fourth clutch drive hub (6) and clutch disc (4) with forward clutchclearance gauge.Clutch running clearance should be 0.094-0.148 in. (2.387-3.759 mm).

NOTEPerform steps 10 through 12 only if clutch running clearance isincorrect.

If clearance exceeds 0.148 in. (3.759 mm), replace clutch plates (5) and clutch discs (4) with new,thicker clutch plates (5) and clutch discs (4).If clearance still exceeds 0.148 in. (3.759 mm) after completing step 10, replace piston (10) with new,thicker piston (10).

If clearance is less than 0.094 in. (2.387 mm), replace piston (10) with a new, thinner piston (10).Remove snapring (7), fourth clutch drive hub (6), six clutch discs (4), and six clutch plates (5) fromforward clutch housing (16).

Place piston return spring (14) and spring retainer (13) in forward clutch housing (16).Place compressor tool on spring retainer (13) and arbor press.

Compress piston return spring (14) with compressor tool and arbor press and install springretainer (13) with snapring (11).Remove compressor tool from spring retainer (13).

NOTEUse oil-soluble grease to hold bearing race and bearing in place.

Soak six clutch discs in clean OE/HDO-10 lubricatingtransmission oil for at least two minutes before installing inforward clutch housing.

Perform step 18 for transmissions with single-piece bearingassembly.

Install bearing assembly (9) in forward clutch housing (16). Ensure lube scallops of bearingassembly (9) face down.

TM 9-2320-272-24-4


NOTEPerform steps 19 through 21 for transmission with three-piecebearing.

19. Install bearing race (8) in forward clutch housing (16). Ensure outer lip of bearing race (8) isinstalled first.

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20. Install bearing race (3) on forward clutch hub (4). Ensure flat side of bearing race (3) is installed first.

21. Apply liberal amount of oil-soluble grease on bearing (2) and install bearing (2) on forward clutchhub (4).

22. Install forward clutch hub (4) in forward clutch housing (1). Ensure splined edge is installed first.

23. Starting with clutch plate (5), alternately install six clutch plates (5) and six clutch discs (6) inforward clutch housing (1).

24. Install fourth clutch drive hub (7) in forward clutch housing (1) with snapring (8).

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25. Install PTO gear snapring (12) on forward clutch housing (1).26. Slide PTO gear (13), chamfered end first, over PTO gear snapring (12) on forward clutch housing (1).

Ensure PTO gear snapring (12) springs outward into internal groove of PTO gear (13).

NOTEPerform step 27 for transmissions with single-piece bearingassembly.

27. Install roller bearing (17) on forward clutch hub (4).

NOTEPerform steps 28 and 29 for transmission with three-piecebearing.Use oil-soluble grease to hold bearing race, bearing, and sealrings in place.

28. Install bearing race (14), flat side first, on forward clutch hub (4).

29. Install bearing (15) and bearing race (16) on forward clutch hub (4).

30. Install two new seal rings (10) on turbine shaft (11).31. Install new seal ring (9) on turbine shaft (11).

Install forward clutch housing (1) and turbine shaft (11) in transmission housing while engaging fourth clutchdrive hub (7) with internal-splined clutch discs of fourth clutch. Ensure the fourth clutch housing (1) isproperly seated.

FOLLOW-ON TASK: Install transmission oil pump and front support (para. 5-46).

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5-48. FOURTH CLUTCH MAINTENANCE

THIS TASK COVERS:


d. Assemblye . Ins ta l la t ion

INITIAL SETUP:


SPECIAL TOOLSSpring compressor (Appendix E, Item 95)Fourth clutch clearance gauge (Appendix E,

Item 47)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Vernier caliper (Appendix E, Item 159)Depth gauge (Appendix E, Item 81)Spring tester (Appendix E, Item 131)Arbor press

EQUIPMENT CONDITIONForward clutch removed (para. 5-47).


GENERAL SAFETY INSTRUCTIONSUse care when removing piston return spring.Spring is under great compression.

MATERIALS/PARTSPiston inner seal ring (Appendix D, Item 515)Piston outer seal ring (Appendix D, Item 516)Lubricating oil (Appendix C, Item 47)Oil-soluble grease (Appendix C, Item 53)

1. Lift fourth clutch (1) straight out of transmission (4).NOTE

Perform step 2 for transmissions with two-piece bearing.

2. Remove bearing race (2) and bearing assembly (3) from fourth clutch (1) or transmission (4).NOTE

Perform step 3 for transmissions with single-piece bearingassembly.

3. Remove bearing assembly (3) from fourth clutch (1) or transmission (4).

1. Position piston return spring compressor on spring retainer (5) and place on arbor press.

WARNING

Piston return spring is under great compression. Do not removesnapring until pressure is applied to spring retainer. If not, pistonreturn spring may fly out, causing injury to personnel.

2. Apply pressure to spring retainer (5) and remove snapring (6) from fourth clutch (1).

3. Carefully remove piston return spring compressor.4. Remove spring retainer (5), piston return spring (7), and optional spacer (8) from fourth clutch

housing (1).

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5-48. FOURTH CLUTCH MAINTENANCE (Contd)

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5. Remove backplate snapring (1) from fourth clutch housing (5).CAUTION

The fourth clutch consists of a backplate, five clutch plates, andfive clutch discs. Keep all clutch parts together. Intermixing fourthclutch parts with any other clutch part will cause transmissiondamage.

NOTETag all fourth clutch parts for reassembly.

6. Remove backplate (2), five clutch plates (4), five clutch discs (3), and piston (8) from fourth clutchhousing (5).

7. Remove piston outer seal ring (7) from piston (8). Discard seal ring (7).8. Remove piston inner seal ring (6) from fourth clutch housing (5). Discard seal ring (6).

1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Inspect five clutch plates (4) for burned surfaces. If burned, discard clutch plates (4).4. Inspect five clutch discs (3) for burned surfaces. If surface of clutch disc (3) is burned, discard clutch

disc (3).5. Inspect piston return spring (9) for discoloration due to overheating. If discolored, discard piston

return spring (9).6. Inspect piston return spring (9) for broken coils or coils distorted due to wear. If coils are broken or

distorted, discard piston return spring (9).NOTE

Free length of piston return spring is 3.22 in. (81.8 mm).7. Using spring tester, inspect piston return spring (9) for serviceability.

a. Compress piston return spring (9) to 1.28 in. (32.5 mm).b. If piston return spring (9) does not give load of 158-178 lb (703-791 N), discard.

8. Measure backplate (2) thickness. If backplate (2) thickness is less than .248 in. (6.30 mm), discard.

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NOTEEnsure new seal ring lips face toward oil pressure side of piston.

1. Apply oil-soluble grease to new piston outer seal ring (11) and install new piston outer seal ring (12)on piston (10).

2. Apply oil-soluble grease to new piston inner seal ring (12) and install new piston inner seal ring (12)in fourth clutch housing (5).

3. Install piston (10) in fourth clutch housing (5).

NOTESteps 4 through 9 obtain clutch running clearance.

4. Starting with clutch plate (9), alternately install five clutch plates (9) and five clutch discs (8) infourth clutch housing (5).

5. Position backplate (7) in fourth clutch housing (5) and install with snapring (6).6. Measure clearance between backplate (7) and clutch disc (8). Clearance should be 0.68-0.127 in.

(17.27-3.226 mm).7. If clearance exceeds 0.127 in. (3.226 mm), replace clutch discs (8) and clutch plates (9) with new,

thicker clutch discs (8) and plates (9).8. If clearance still exceeds 0.127 in. (3.226 mm) after completing step 7, replace piston (10) with new,

thicker piston (10).9. If clearance is less than 0.68 in. (17.27 mm), replace piston (10) with new, thinner piston (10).

10. Remove snapring (6), backplate (7), five clutch discs (8), and five clutch plates (9) from fourth clutchhousing (5).

NOTESoak five clutch discs in clean OE/HDO-10 lubricating oil for at leasttwo minutes before installing in fourth clutch housing.

11. Starting with clutch plate (9), alternately install five clutch plates (9) and clutch discs (8) in fourthclutch housing (5).

12. Place optional spacer (4), piston return spring (3), and spring retainer (2) in fourth clutch housing (5).13. Position piston return spring compressor on spring retainer (2) and arbor press, and compress piston

return spring (3).14. Install spring retainer (2) in fourth clutch housing (5) with snapring (1).15. Remove piston return spring compressor from spring retainer (2).

NOTEPerform step 1 for transmission with single-piece bearingassembly.

1. Placing race section of bearing assembly (14) into transmission housing (15) first, install bearingassembly (14) in transmission housing (15).

NOTEPerform step 2 for transmission with two-piece bearing.Use oil-soluble grease to hold bearing race in place.

2. Install bearing race (13) and bearing assembly (14) on fourth clutch housing (5). Ensure bearingrace (13) is installed outer lip first.

3. Install fourth clutch housing (5) in transmission housing (15).

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FOLLOW-ON TASK: Install forward clutch. (para. 5-47).

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5-49. THIRD CLUTCH MAINTENANCE

THIS TASK COVERS:

a. Removalb. Cleaning and Inspection

c . Ins ta l la t ion

INITIAL SETUP:


SPECIAL TOOLSThird clutch clearance gauge (Appendix E,

Item 139)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Outside micrometer (Appendix E, Item 80)Spring tester (Appendix E, Item 131)

EQUIPMENT CONDITIONFourth clutch removed (para. 5-48).


CAUTION

Keep all clutch parts together. Intermixing third clutch parts withany other clutch pack will cause transmission damage.

NOTETag all clutch parts for reassembly.

Mark position of all clutch plates in transmission housing forreassembly.

1. Remove snapring (1), backplate (2), three clutch discs (3), and clutch plates (5) from transmissionhousing (4).



3. Inspect clutch discs (3) for burned surfaces. If burned, discard clutch discs (3).4. Inspect clutch plates (5) for burned surfaces. If burned, discard clutch plates (5).5. Measure backplate (2) thickness.

a. If thickness of backplate (2) marked No. 7 is less than 0.476 in. (12.09 mm), discard backplate (2).b. If thickness of backplate (2) marked No. 8 is less than 0.450 in. (11.43 mm), discard backplate (2).

c. If thickness of backplate (2) marked No. 9 is less than 0.463 in. (11.76 mm), discard backplate (2).

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5-49. THIRD CLUTCH MAINTENANCE (Contd)

1. Starting with clutch plate (5), alternately install three clutch plates (5) and three clutch discs (3) intransmission housing (4).

2. Install backplate (2) and snapring (1) in transmission housing (4).3. Measure clearance between backplate (2) and snapring (1) with third clutch clearance gauge. Third

clutch clearance should be 0.050-0.114 in. (1.270-2.896 mm).

4. If third clutch clearance exceeds 0.114 in. (2.896 mm), replace clutch discs (3) with new, thickerdiscs (3).

5. If third clutch clearance still exceeds 0.114 in. (2.896 mm) after completing step 4, replace back-plate (2) with new, thicker backplate (2).

6. If third clutch clearance is less than 0.050 in. (1.270 mm), replace backplate (2) with new, thinnerbackplate (2).

FOLLOW-ON TASK: Install fourth clutch (para. 5-48).

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5-50. CENTER SUPPORT MAINTENANCE


d. Assemblye . Ins ta l la t ion

INITIAL SETUP:

APPLICABLE MODELS MATERIALS/PARTSAll

SPECIAL TOOLSBushing installer (Appendix E, Item 24)Retainer ring depth tool (Appendix E, Item 114)Center support lifter (Appendix E, Item 27)Compressor bar and screw (Appendix E,

Item 29)Compressor base (Appendix E, Item 30)Snapring gauge (Appendix E, Item 124)

TOOLSGeneral mechanic’s tool kit (Appendix E,

Item 1)Spring tester (Appendix E, Item 131)Depth gauge (Appendix E, Item 81)Torque wrench (Appendix D, Item 144)Arbor pressHoist

Seal ring (Appendix D, Item 641)Bushing (Appendix D, Item 27)Eight self-locking retainers (Appendix D, Item 647)Filter screen (Appendix D, Item 126)Two piston inner seal rings (Appendix D, Item 258)Two piston outer seal rings (Appendix D, Item 509)Checkball (Appendix D, Item 37)Two step-joint seal rings (Appendix D, Item 638)Chamfered washer (Appendix D, Item 35)Anchor bolt (Appendix D, Item 5)Oil-soluble grease (Appendix C, Item 53)


1. Remove center support anchor bolt (3) or (4) and washer (5) or (2) from transmissionhousing (1). Discard anchor bolt (3) or (4) and washer (5) or (2).

NOTEIf old style hex-head bolt and washer were present, center supportmust be rethreaded. Refer to task c.

2. Remove snapring (6) from transmission housing (1).3. Attach center support lifter to center support (7) and remove center support (7) from transmission

housing (1).NOTE

Record location of any shims present.

EQUIPMENT CONDITIONThird clutch removed (para. 5-49).


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5-50. CENTER SUPPORT MAINTENANCE (Contd)

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1.

2.3.

4.

5.

6.

7.8.

Remove filter screen (14) and seal ring (13) from center support (10). Discard filter screen (14) andseal ring (13).

NOTEThe second and third clutch pistons are disassembled thesame way. This procedure covers the second clutch piston.

Remove second clutch piston (11) from center support (10).Remove inner seal ring (5) and outer seal ring (6) from second clutch piston (11). Discard sealrings (5) and (6).Remove four self-locking retainers (1) from pins (12) on second clutch piston (11). Discard self-lockingretainers (1).

Remove retainer (2) and twenty springs (3) from second clutch piston (11).Remove two step-joint seal rings (7) from center support (10). Discard step-joint seal rings (7).

NOTEBushing is removed only if it fails inspection (task c).Mark location of bushing notch on center support forreassembly.

Replace checkball if bushing is replaced.Press bushing (8) out of center support (10) with arbor press and mandrel. Discard bushing (8).Remove checkball (9) from center support (10). Discard checkball (9).

1.2.3.

4.

5.

6.

For general cleaning instructions, refer to para. 2-14.For general inspection instructions, refer to para. 2-15.Inspect center support (10) cavities for obstruction or foreign material. Remove obstruction orforeign material.

Measure depth of anchor bolt hole in center support (10). If hole is not 1.610 in. (40.89 mm) deep,rework center support (10) as follows:

a. Drill 1.610 in. (40.89 mm) hole in center support (10).

b. Counterbore 0.469 in. (11.91 mm) diameter 0.66-0.70 in. (16.8-17.8 mm) deep.c. Tap hole using 3/8 in. (9.53 mm) tap UNC2B min. Full thread to depth of dim. A.Inspect four pins (12) on each piston (4) and (11) for bends and breaks. If any pin (12) is damaged,replace piston (4) or (11).Inspect all springs (3) for discoloration due to overheating. If discoloration is present, discardsprings (3).

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7. Inspect all springs (6) for broken coils or coils distorted due to wear. If spring (6) is broken ordistorted, discard.

8. Using spring tester, inspect all springs (6) for serviceability.a. Compress spring (6) to 0.81 in. (20.7 mm) and check load.

b. If spring (6) does not give load of 4.30-5.70 lb (19.1.-25.4 N), discard.

d. Assembly

1.

2.

3.4.

5.

6.

7.8.

9.

10.

11.

NOTEPerform steps 1 and 2 only if bushing was removed.Checkball will be installed when new bushing is pressed in.

Position checkball (2) in center support (3) and align notch on new bushing (1) with marked locationon center support (3).

Press new bushing (1) in center support (3) with bushing installer and arbor press until flush.NOTE

The second and third clutch pistons are assembled the same way.This procedure covers the second clutch piston.

Place second clutch piston (10) in center support (3).Place twenty springs (6) in pockets on piston (11).

Align spring retainer (5) with pins (11) on piston (10) with retainer ring depth tool and install fournew self-locking retainer rings (4)

Remove second clutch piston (10) from center support (3).

Apply oil-soluble grease to new inner seal ring (8) and new outer seal ring (9).Install new inner seal ring (8) and new outer seal ring (9) on second clutch piston (10). Ensure lipsof seal rings (8) and (9) face toward center support (3) when second clutch piston (10) is installed.Repeat steps 3 through 8 to assemble third clutch piston (7).

NOTEDo not install third clutch piston in center support at this time.

Install second clutch piston (11) in center support (3).NOTE

Install new filter screen (13) and new seal ring (12) on center support (3).

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e. Installation

NOTETilt front end of transmission housing upward before beginninginstallation.

1. Attach center support lifter to center support (4).NOTE

Ensure center support is seated firmly against second clutchsnapring.Do not use old-style washer or hex-head anchor bolt.

2. Carefully position center support (4) in transmission housing (5) with the anchor bolt hole (6) oncenter support (4) and transmission housing center support hole (14) aligned.

3. Install center support (4) in transmission housing (5) with new chamfered washer (13) and anchorbolt (12). Tighten anchor bolt (13) finger-tight.

4. Remove center support lifter from center support (4).5. Position compressor base (9) on center support (4).6. Install compressor bar (10) and screw (8) on transmission housing (5) with two screws (11).7. Tighten compressor screw (8) 5 lb-ft (7 N•m).

8. Measure clearance between top edge of center support (4) and top of center support snapringgroove (7) in transmission housing (5) with snapring gauge.

NOTERefer to table 5-14 to select. correct size snapring to be installed instep 12.

9. Release pressure from center support (4) by loosening compressor screw (8).10. Remove compressor bar screws (11), compressor bar (10) and screw (8), and compressor base (9)

from center support (4).

11. Install third clutch piston (2) in center support (4).

12. Install center support snapring (1) in transmission housing (5). Ensure snapring (1) is fully seated.

13. Tighten anchor bolt (12) 39-46 lb-ft (53-62 N•m)

14. Apply liberal amount of oil-soluble grease on two new step-joint seal rings (3), and install two newstep-joint seal rings (3) on hub of center support (4).

Table 5-14. Center Support Snapring.

MEASURED SNAPRINGCLEARANCE THICKNESS

0.150-0.154 in. 0.148-0.150 in.(3.81-3.91 mm) (3.76-3.81 mm)

0.154-0.157 in. 0.152-0.154 in.(3.91-3.99 mm) (3.86-3.91 mm)

0.157-0.160 in. 0.155-0.157 in.(3.99-4.06 mm) (3.94-3.99 mm)

0.160-0.164 in. 0.158-0.160 in.(4.06-4.17 mm) (4.01-4.06 mm)

SNAPRINGCOLOR

White

Yellow

Green

Red

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FOLLOW-ON TASK: Install third clutch (para. 5-49).

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5-51. GEAR UNIT AND MAIN SHAFT MAINTENANCE

THIS TASK COVERS:

a. Removal d. Assemblyb. Disassembly e . Ins ta l la t ionc. Cleaning and Inspect ion

INITIAL SETUP:


SPECIAL TOOLSGear unit lifter (Appendix E, Item 58)

ToolsGeneral mechanic’s tool kit (Appendix E, Item 1)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)Snapring pliers (Appendix E, Item 125)

MATERIALS/PARTSOil-soluble grease (Appendix C, Item 53)


EQUIPMENT CONDITIONCenter support removed (para. 5-50).


a . R e m o v a l

Attach gear unit lifter to gear unit main shaft (1) and remove gear unit (2) from transmission housing (3).

b. Disassembly

1. Remove thrust washer (4), front sun gear (5), sun gear shaft (7), and thrust washer (6) from frontplanetary carrier (8).

2. Remove front planetary carrier (8) and thrust washer (9) from planetary carrier drum (10).

3. Remove snapring (12) from ring gear (13) and lift ring gear (13) out of planetary carrier drum (10).4. Remove center planetary carrier (11) from planetary carrier drum (10).5. Remove roller bearing (14) and bearing race (15) from main shaft (18).6. Remove snapring (19) from main shaft (18) and slide lower planetary sun gear (20) off main shaft (18).

7. Remove main shaft (18) from rear planetary sun gear (23).8. Remove center ring gear (17) and rear planetary sun gear (23) from rear planetary carrier (22).

9. Remove snapring (16) from center ring gear (17) and slide rear planetary sun gear (23) out of centerring gear (17).

10. Remove snapring (21) from rear planetary carrier (22) and lift rear planetary carrier (22) out ofplanetary carrier drum (10).

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5-51. GEAR UNIT AND MAIN SHAFT MAINTENANCE (Contd)

5-349

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1.2.3.

4.

5.

6.7.

8.

9.


Measure thickness of thrust washer (11). If thrust washer (11) thickness is less than 0.092 in.(2.354 mm), discard thrust washer (11).Measure clearance from thrust washer (11) to front sun gear (10). If clearance from thrustwasher (11) to front sun gear (10) exceeds 0.005 in. (0.127 mm), discard thrust washer (11).Measure thickness of thrust washers (6) and (9). If thickness is less than 0.091 in. (2.31mm),discard thrust washers (6) and (9).

Inspect thrust washers (6) and (9) for scoring. If scored, discard thrust washers (6) and (9).

Measure clearance of two sun gear shaft bushings (4) on main shaft (5). If clearance exceeds0.006 in. (0.152 mm), discard two sun gear shaft bushings (4).

Measure clearance of front planetary carrier (7) bushing (8) on front sun gear (10). If clearanceexceeds 0.005 in. (0.127 mm), discard front planetary carrier (7) bushing (8).Measure clearance of sun gear shaft (3) on center support bushing. (2). If clearance exceeds 0.006 in.(0.152 mm), discard sun gear shaft (3), or replace bushing (2) in center support (1) (para. 5-50).

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d. Assembly

1.

2.

3.

4.5.

6.

Position rear planetary carrier (18) in short splined end of planetary carrier drum (17) and installwith snapring (21).Position rear planetary sun gear (16) in center ring gear (15) until seated and install withsnapring (14).

Install center ring gear (15) in planetary carrier drum (17), until seated against rear planetarycarrier (18).Install main shaft (22) into rear planetary sun gear (16), ensuring smaller end is installed first.

Install lower planetary sun gear (20) on rear of main shaft (22) with snapring (19).NOTE

Use oil-soluble grease to hold bearing race and bearing in place.

Install bearing race (13) and bearing (12) on main shaft (22). Ensure lip of bearing race (13) facesaway from center ring gear (15).

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7.

8.

9.10.11.12.

13. Install sun gear shaft (10) over main shaft (8) in planetary carrier (9) until seated against bearing.

14 . Install thrust washer (1) on sun gear (2) and over the gear shaft (10).

Install center planetary carrier (11) in long splined end of planetary carrier drum (9).

Place front planetary ring gear (7) in planetary carrier drum (9) over center planetary carrier (11)and install with snapring (6).

NOTEUse oil-soluble grease to hold thrust washers in place.

Install thrust washer (5) on front planetary carrier (4).Install front planetary carrier (4) in planetary carrier drum (9).

Install thrust washer (3) on sun gear (2).Install front sun gear (2) on sun gear shaft (10). Ensure spring pin on sun gear shaft (10) is alignedwith wide spline on front sun gear (2).

NOTEEnsure sun gear teeth and front planetary pinion teeth are flushand the front of the sun gear shaft is past groove between doublesplines on the main shaft.

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e. Installation

1. Attach gear unit lifter to gear unit main shaft (12).

2. Carefully lower gear unit (13) into transmission housing (14) with hoist. Ensure all gear teeth (15)mesh.

3. Remove gear unit lifter from gear unit main shaft (12).

FOLLOW-ON TASK: Install center support (para. 5-50).

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5-52. SECOND CLUTCH MAINTENANCE

THIS TASK COVERS:

a. Removal c. Installationb. Cleaning and Inspection d. Establishing Clearance

INITIAL SETUP:


SPECIAL TOOLSSecond clutch clearance gauge (Appendix E,

Item 118)

EQUIPMENT CONDITIONGear unit and main shaft removed (para. 5-51).


TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)

a. Removal

CAUTION

Second clutch consists of a backplate, four clutch plates, and fourclutch discs. Keep all clutch parts together. Intermixing secondclutch parts with any other clutch pack will cause transmissiondamage.

NOTETag all second clutch parts for reassembly.

Remove snapring (l), four clutch discs (5), clutch plates (2), and backplate (4) from transmission housing (3).


Flying rust and metal particles may cause injury to personnel.



3. Inspect clutch plate (2) for burned surfaces. If burned, discard clutch plate (2).4. Inspect clutch discs (5) for burned surfaces. If burned, discard clutch disc (5).5. Measure backplate (4) thickness.

a. If thickness of backplate (4) marked No. 10 is less than 0.234 in. (5.94 mm), discard backplate (4).b. If thickness of backplate (4) marked No. 11 is less than 0.208 in. (5.28 mm), discard backplate (4).

b. If thickness of backplate (4) marked No. 12 is less than 0.221 in. (5.61 mm), discard backplate (4).

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5-52. SECOND CLUTCH MAINTENANCE (Contd)

5-355

TM 9-2320-272-24-4


c. Installation

1. Install backplate (3) in transmission housing (2). Ensure that flat side of backplate (3) is up.2. Starting with clutch disc (1), alternately install four clutch discs (1) and four clutch plates (5) in

transmission housing (2).

3. Install snapring (4) on top of clutch plates (5).

d. Establishing Clearance

NOTEAdapter housing and first clutch must be removed to establishsecond clutch clearance. Refer to paras. 5-57 and 5-53.Tilt rear end of transmission housing upward in order toestablish clearance.

1. Measure clearance between backplate (3) and transmission housing (2). Clearance should be0.059-0.129 in. (1.49-3.28 mm).

2. If second clutch clearance exceeds 0.059-0.129 in. (1.49-3.28 mm), replace clutch discs (1) with new,thicker clutch discs (1).

3. If clutch clearance still exceeds 0.129 in. (3.28 mm) after completing step 1, replace backplate (3)with new, thicker backplate.

4. If clearance is less than 0.059 in. (1.49 mm), replace backplate (3) with new, thinner backplate (3).5. If first clutch and adapter housing were removed to establish second clutch clearance, install them

(paras. 5-57 and 5-53).

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FOLLOW-ON TASK: Install gear unit and main shaft (para. 5-51).

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5-53. FIRST CLUTCH MAINTENANCE

THIS TASK COVERS:

a. Removalb . C l e a n i n g a n d I n s p e c t i o n

c . Ins ta l la t iond. Establ ishing Clearance

INITIAL SETUP:


SPECIAL TOOLSFirst clutch clearance gauge (Appendix E,

Item 45)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Outside micrometer (Appendix E, Item 80)Vernier caliper (Appendix E, Item 159)Snapring pliers (Appendix C, Item 125)


EQUIPMENT CONDITIONSecond clutch removed (para. 5-52).


CAUTION

First clutch consists of a backplate, six clutch plates, and six clutchdiscs. Keep all clutch parts together. Intermixing first clutch partswith any other clutch pack will cause transmission damage.

a. Removal

NOTE

Tag all first clutch parts for reassembly.Backplate, five clutch discs, four clutch plates, andrear planetary ring gear are removed as one unit.

1. Remove snapring (5), backplate (6), five clutch discs (3), four clutch plates (2), and rear planetaryring gear (1) from transmission housing (4).

2. Remove remaining two clutch plates (2) and clutch disc (3) from transmission housing (4).



2. For general inspection instructions, refer to para. 2-15.3. Inspect clutch discs (3) for burned surfaces. If surfaces are burned, discard clutch discs (3).4. Inspect clutch plate (2) for burned surfaces. If surfaces are burned, discard clutch plate (2).

NOTECast iron backplates marked number 1, 2, and 3 must have samethickness as corresponding new malleable iron backplates 4,5, and 6.

5. Measure backplate (6) thickness.a. If thickness of backplate (6) marked No. 4 is less than 0.702 in. (17.83 mm), discard backplate (6).b. If thickness of backplate (6) marked No. 5 is less than 0.671 in. (17.04 mm), discard backplate (6).c. If thickness of backplate (6) marked No. 6 is less than 0.640 in. (16.26 mm), discard backplate (6).

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5-53. FIRST CLUTCH MAINTENANCE (Contd)

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c. Installation

1. Starting with clutch plate (2), alternately install two clutch plates (2) and one clutch disc (3) intransmission housing (1).

2. Install rear planetary ring gear (4) in transmission housing (1). Ensure all clutch plate (2) tangsand clutch disc (3) splines mesh.

3. Starting with clutch disc (3), alternately install five clutch discs (3) and four clutch plates (2) on rearplanetary ring gear (4).

4. Install backplate (6) and snapring (5) in transmission housing (1). Ensure flat side of backplate (6) isinstalled first.

d. Establishing Clearance

1. Measure clearance between snapring (5) and backplate (6) with first clutch clearance gauge. Clutchrunning clearance should be 0.074-0.147 in. (1.880-3.374 mm).

2. If clutch running clearance exceeds 0.147 in. (3.734 mm), replace clutch plates (2) and discs (3) withnew, thicker plates (2) and discs (3).

3. If clutch running clearance still exceeds 0.147 in. (3.374 mm) after completing step 2, replacebackplate (6) with new, thicker backplate (6).

4. If clutch running clearance is less than 0.074 in. (3.374 mm), replace backplate (6) with new,thinner backplate (6).

5-360

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FOLLOW-ON TASK: Install second clutch (para. 5-52).

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5-54. TRANSMISSION GOVERNOR REPLACEMENT

THIS TASK COVERS


INITIAL SETUP:


TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1) First clutch removed (para. 5-53)Torque wrench (Appendix E, Item 146)

MATERIALS/PARTSGovernor cover gasket (Appendix D, Item 241)


a. Removal

1. Remove four screws (3), governor cover (4), and gasket (5) from transmission rear cover (2). Discardgasket (5).

2. Rotate transmission governor (6) clockwise to disengage, and remove transmission governor (6) fromtransmission rear cover (2).

b. Installation

NOTEGovernor is properly seated only after counterclockwise rotation ofgovernor gear is felt during installation.

1. Insert plastic gear (7) end of transmission governor (6) into transmission governor bore (1) and pushinward. Ensure governor (6) is properly seated.

2. Install new gasket (5) and governor cover (4) on transmission rear cover (2) with four screws (3).Tighten screws (3) 15-20 lb-R (20-27 N•m).

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5-54. TRANSMISSION GOVERNOR REPLACEMENT (Contd)

FOLLOW-ON TASK: Install first clutch (para. 5-53).

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TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE

THIS TASK COVERS:a . Remova lb. Disassembly

c. Cleaning and Inspectiond. Assembly

INITIAL SETUP:

APPLICABLE MODELS MATERIALS/PARTSAll

SPECIAL TOOLSDriver handle (Appendix E, Item 38)Spring compressor (Appendix E, Item 31)Rear bearing installer (Appendix E, Item 115)Driver handle (Appendix E, Item 37)Seal remover (Appendix E, Item 92)Converter turbine bearing puller

(Appendix E, Item 105)Pin remover (Appendix E, Item 94)Bearing installer (Appendix E, Item 10)‘Iwo guide pliers (Appendix E, Item 59)

ToolsGeneral mechanic’s tool kit (Appendix E, Item 1)Outside micrometer (Appendix-E, Item 80)Vernier calipers (Appendix E, Item 159)Spring tester (Appendix E, Item 131)Torque wrench (Appendix E, Item 144)Arbor press

Low clutch piston inner seal ring(Appendix D, Item 259)

Low clutch piston outer seal ring(Appendix D, Item 509)

Gasket (Appendix D, Item 228)Crocus cloth (Appendix C, Item 20)Oil-soluble grease (Appendix C, Item 53)


EQUIPMENT CONDITIONTransmission governor removed (para. 5-54).Transmission output shaft oil seal removed(para. 4-78).


a . R e m o v a l

NOTETurn transmission housing with rear cover facing upward.

1. Remove fourteen screws (1) and washers (5) from rear cover (2).

NOTEClean gasket remains from mating surfaces.

2. Remove rear cover (2), low planetary carrier (9), gasket (4), and thrust washer (10) fromtransmission housing (3). Discard gasket (4).

3. Remove sleeve spacer (6), speedometer drive gear (7), and governor drive gear (8) from lowplanetary carrier (9).

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TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE (Contd)

5-365

TM 9-2320-272-24-4


b. Disassembly

1. Remove dust cover (11) and oil seal (10) from rear cover (1) with seal puller and hook.

2 . Remove beveled snapring (9) and rear output shaft bearing (8) from rear cover (1) with converterturbine bearing puller.

3. Position spring compressor and arbor press on low clutch spring retainer (3) and apply pressure tospring retainer (3).

4. Remove snapring (2) and spring compressor from low clutch spring retainer (3).5. Remove low clutch spring retainer (3) and twenty-six piston return springs (4) from low clutch

piston (5).6. Remove low clutch piston (5) from rear cover (1).

7. Remove outer seal ring (6) and inner seal ring (7) from low clutch piston (5). Discard seal rings (6)and (7).

8. Remove plug (13), drain tube (12), and plug (17) from rear cover (1).9. Remove filter plug (14), O-ring (15), and governor filter (16) from rear cover (1).

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TM 9-2320-272-24-4


5-367

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1.2.3.4.

5.

6.

7.8.

9.10.11.

12.13.

14.

15.

For general cleaning instructions, refer to para. 2-14.For general cleaning instructions, refer to para. 2-15.Inspect rear cover (1) for breaks and cracks. Replace rear cover (1) if broken or cracked.Measure governor clearance in bore (2) of rear cover (1). Replace rear cover (1) if clearance exceeds.0035 in. (.0089 mm).

Inspect governor support pin (9) for looseness, bends, and breaks. Replace governor support pin (9)with pin remover if loose, bent, or broken.

Inspect low planetary carrier (5) for missing or twisted splines (6). Replace low planetary carrier (5)if splines (6) are missing or twisted.Inspect low planetary carrier (5) for burrs. If burrs are found, remove using crocus cloth.Inspect roller bearing (7) on low planetary carrier (5) and race (8) in rear cover (1). Replacebearing (7) and race (8) as a set if defective.

NOTEPerform steps 9 and 10 only if bearing or race is defective.Pin must be removed to remove bearing.

Remove pin (4) and roller bearing (7) from low planetary carrier (5). Discard pin (4).Remove race (8) from rear cover (1) using bearing puller.Measure thrust washer (3) thickness. Discard thrust washer (3) if thickness is less than 0.091 in.(2.31mm).Inspect thrust washer (3) for scoring. Discard if scored.Inspect twenty-six piston return springs (10) for discoloration due to overheating. Discard pistonreturn springs (10) if discolored.Inspect twenty-six piston return springs (10) for broken coils or coils distorted due to wear. Discardpiston return springs (10) if broken or distorted.

Inspect twenty-six piston return springs (10) for serviceability by checking load when compressedwith spring tester. Discard spring (10) if spring (10) does not give load according to table 5-15,Spring Data.


SPRING

Piston return spring

COLOR FREE LENGTH COMPRESSED LENGTH UNDER LOAD

Solid orange, 1.28 in. 0.95 in. 13.6-16.4 lbyellow stripe (32.5 mm) (24.1 mm) (60.5-72.9 N)

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TM 9-2320-272-24-4


d . A s s e m b l y

1. Install governor filter (6), O-ring (5), and filter plug (4) in rear cover (1). Tighten filter plug (4)50-70 lb-ft (68-95 N•m).

2. Install drain tube (2) and plug (3) in rear cover (1). Tighten plug (3) 12-16 lb-ft (16-22 N•m).3. Install plug (7) in rear cover (1). Tighten plug (7) 4-8 lb-ft (5-11 N•m).

NOTEPerform step 4 only if support pin was previously removed.

4. Using pin installer, press new governor support pin (11) into rear cover (1) until end of pin (11) is5.886-5.896 in. (14.950-14.975 cm) from outside face (12) of rear cover (1).

NOTEPerform steps 5 and 6 only if bearing and bearing race werepreviously removed.

5. Using bearing race installer, install bearing outer race (13) in rear cover (1).NOTE

Install roller bearing before installing pin.6. Install roller bearing (10) and new pin (8) on low planetary carrier (14). Seat roller bearing (10) to

shoulder on shaft (9).7. Install new thrust washer (15) if discarded during inspection.

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TM 9-2320-272-24-4


5-371

TM 9-2320-272-24-4


8.9.

10.11.12.

Install new outer seal ring (6) and new inner seal ring (7) on low clutch piston (5).

Place low clutch piston (5) in rear cover (1).

Place twenty-six piston return springs (4) in low clutch piston (5).Place cupped side of clutch spring retainer (3) over piston return springs (4).Place spring compressor and snapring (2) on clutch spring retainer (3) and compress twenty-six pistonreturn springs (4).

13. Install clutch spring retainer (3) with snapring (2).

14. Remove spring compressor from clutch spring retainer (3).

15. Install rear output shaft bearing (8) in rear cover (1) with bearing installer until seated.

16. Install beveled snapring (9) in rear cover (1) with beveled side toward rear of transmission.

17. Install oil seal (10) and dust shield (11) in rear cover (1).

18. Install rear cover and low planetary carrier (para. 5-58).

NOTEEnsure seal rings and lips face piston oil pressure side.Use oil-soluble grease to hold in place.

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TM 9-2320-272-24-4


FOLLOW-ON TASKS: Install transmission governor (para. 5-54).Install transmission output shaft oil seal (para. 4-78).

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TM 9-2320-272-24-4

5-56. LOW CLUTCH REMOVAL AND CLEARANCE

THIS TASK COVERS:

a . Remova l c. Establishing Clearanceb. Cleaning and Inspection

INITIAL SETUP:


TOOLS EQUIPMENT CONDITIONGeneral mechanic’s tool kit (Appendix E, Item 1)Depth micrometer (Appendix E, Item 81)

Rear cover and low planetary carrier removed(para. 5-55).

MATERIALS/PARTSGasket (Appendix D, Item 228)


a. Removal

1. Remove low planetary ring gear (1), snapring (3), and low gear ring hub (2) from adapterhousing (6).

NOTEMark position of clutch plates in adapter housing for installation.

2. Remove eight clutch plates (4) and seven clutch discs (5) from adapter housing (6).




3. Inspect clutch discs (5) for burned surfaces. If burned, discard clutch discs (5).

4. Inspect clutch plates (4) for burned surfaces. If burned, discard clutch plates (4).

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5-56. LOW CLUTCH REMOVAL AND CLEARANCE (Contd)

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TM 9-2320-272-24-4


c. Establishing Clearance

1.

2.

3.4.

5.

6.

Starting with clutch plate (2), alternately install eight clutch plates (2) and seven clutch discs (3) inadapter housing (1).Measure distance from top edge of adapter housing (1) to top of clutch plate (2) with depthmicrometer. Record measurement.Position new rear cover gasket (4) on rear cover (5).Measure distance from top of edge of piston (6) to gasket (4) with depth micrometer. Recordmeasurement.Subtract step 4 measurement from step 2 measurement. Record the difference. This measurement islow clutch clearance.

Low clutch clearance, as determined in step 5, should be 0.073-0.141 in. (1.85-3.58 mm). If clutchclearance exceeds 0.141 in. (3.58 mm), replace clutch plates (2) and discs (3) with new, thickerplates (2) and discs (3).

7. Remove eight clutch plates (2) and seven clutch discs (3) from adapter housing (1).

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TM 9-2320-272-24-4


FOLLOW-ON TASK: Install rear cover and low planetary carrier (para. 5-58).

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5-57. ADAPTER HOUSING AND FIRST CLUTCH PISTON MAINTENANCE

THIS TASK COVERS

a . Remova l c. Cleaning and Inspectionb. Disassembly d. Assembly

INITIAL SETUP:


SPECIAL TOOLSSpring compressor (Appendix E, Item 31)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Spring tester (Appendix E, Item 131)Torque wrench (Appendix E, Item 146)Arbor press

MATERIALS/PARTSBasic overhaul kit (Appendix D. Item 10)Adapter housing gasket (Appendix D, Item 228)Oil-soluble grease (Appendix C, Item 53)


EQUIPMENT CONDITIONLow clutch removed (para. 5-56)


a. Removal

Remove adapter housing (1) and gasket (2) from transmission housing (3). Discard gasket (2).

b. Disassembly

1. Position compressor tool on first clutch spring retainer (5) and arbor press.2. Apply pressure to first clutch ring retainer (5), and remove snapring (4) from adapter housing (1).

3. Remove compressor tool from first clutch spring retainer (5).

4. Remove first clutch spring retainer (5) and twenty-six springs (6) from first clutch piston (7).

5. Remove first clutch piston (7) from adapter housing (1).

6. Remove outer seal ring (8) and inner seal ring (9) from first clutch piston (7). Discard inner sealring (9) and outer seal ring (8).

7. Remove plug (10) from adapter housing (1).

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5-57. ADAPTER HOUSING AND FIRST CLUTCH PISTON MAINTENANCE (Contd)

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TM 9-2320-272-24-4



1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Inspect twenty-six piston return springs (4) for discoloration due to overheating. If discolored,

discard piston return springs (4)4. Inspect twenty-six piston return springs (4) for broken coils or coils distorted due to wear. If broken

or distorted, discard piston return springs (4).NOTE

Perform step 5 if springs pass visual inspection.5. Using spring tester, compress each of twenty-six piston return springs (4) to 0.95 in. (24.1 mm) and

check load. If piston return spring (4) does not give the correct load, discard piston return spring (4).Refer to table 5-16, Spring Data.


SPRING COLOR

Piston return Solid orange,spring yellow stripe

FREE LENGTH

1.28 in.(32.5 mm)

COMPRESSED LENGTH

0.95 in.(24.1 mm)

UNDER LOAD

13.6-16.4 lb.(60.5-72.9 N)

d. Assembly

NOTEEnsure seal rings and lips face piston oil pressure side.

Use oil-soluble grease to hold seal rings in place.1. Install new outer seal ring (6) and new inner seal ring (7) on first clutch piston (5).2. Place first clutch piston (5) in adapter housing (1).3. Place twenty-six piston return springs (4) in first clutch piston (5).

4. Place cupped side of spring retainer (3) over piston return springs (4).

5. Place compressor tool on spring retainer (3) and arbor press, and compress twenty-six piston returnsprings (4).

6. Install spring retainer (3) with snapring (2).7. Remove compressor tool from spring retainer (3).8. Install plug (8) in adapter housing (1). Tighten plug (8) 4-8 lb-ft (5-11 N•m).

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TM 9-2320-272-24-4


FOLLOW-ON TASK: Install adapter housing, low clutch, low planetary carrier, and rear cover (para. 5-58).

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TM 9-2320-272-24-4

5-58. ADAPTER HOUSING, LOW CLUTCH, LOW PLANETARY CARRIER, AND REARCOVER INSTALLATION

THIS TASK COVERS:

Installation

INITIAL SETUP:


SPECIAL TOOLSTwo guide pins (Appendix E, Item 59)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 144)

MATERIALS/PARTSTwo gaskets (Appendix D, Item 228)Oil-soluble grease (Appendix C, Item 53)



Installation

1. Install new adapter housing gasket (8) on transmission housing (6).

NOTEGuide pins maintain gasket alignment.

2.3.4.

5.6.

Install two guide pins (7) in transmission housing (6).

Install adapter housing (9) over guide pins (7).Install low ring gear hub (11) and snapring (10) on low planetary ring gear (1).

Install low planetary ring gear (1) into adapter housing (9).Starting with clutch plate (4), alternately install eight clutch plates (4) and seven clutch discs (5) inadapter housing (9).

NOTE

7.8.

9.

10.

11.12.13.

Use oil-soluble grease to hold thrust washer in place.Install thrust washer (3) on low planetary carrier (2) hub.

Install low planetary carrier (2) into adapter housing (9).Install governor drive gear (17), speedometer drive gear (16), and sleeve spacer (15) on lowplanetary carrier (2). Ensure governor drive gear (17) is seated over pin (19).

Install new rear cover gasket (18) and rear cover (14) over guide pins (7) with twelve washers (12)and screws (13). Finger-tighten screws (13).

Remove two guide pins (7) and install remaining two washers (12) and screws (13).Alternately tighten fourteen screws (13) 180° apart. Tighten screws (13) 30 lb-ft (41 N•m).Repeat tightening sequence on fourteen screws (13) 180° apart to achieve final torque. Tightenscrews (13) 81-97 lb-ft (110-132 N•m).

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TM 9-2320-272-24-4

5-58. ADAPTER HOUSING, LOW CLUTCH, LOW PLANETARY CARRIER, AND REARCOVER INSTALLATION (Contd)

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TM 9-2320-272-24-4

5-59. TRANSMISSION HOUSING MAINTENANCE

THIS TASK COVERS:


c. Assembly

INITIAL SETUP:


TOOLS SPECIAL ENVIRONMENTAL CONDITIONSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 146)

Work area clean and free from blowing dirt anddust.

a. Disassembly

Remove four plugs (3) from transmission housing (1).




3. If adapter (2) is defective, replace adapter (2).

c. Assembly

1. Install four plugs (3) in transmission housing (1). Tighten 4-5 lb-ft (5-7 N-m).

NOTEPerform step 2 if early model transmission is to have wide oilpump installed (para. 5-39).

2. Change data plate (4) part number to 23040127.

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TM 9-2320-272-24-4

5-59. TRANSMISSION HOUSING MAINTENANCE (Contd)

5-385

TM 9-2320-272-24-4

5-60. TRANSMISSION OIL PRESSURE TESTING

THIS TASK COVERS:

a. Oil Cooler Pressure Testb. Main Pressure and Governor

Pressure Test

c. Automatic Shift Speed Test

INITIAL SETUP:



SPECIAL TOOLSPressure gauge set (300 psi) (Appendix E,

Item 51)

TOOLS

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Transmission oil at proper level (TM 9-2320-272-10).Vehicle at curb weight (empty) (TM 9-2320-272-10).

General mechanic’s tool kit (Appendix E, Item 1) Wheels blocked (chocked) (TM 9-2320-272-10).Drill press21/64 drill bit SPECIAL ENVIRONMENTAL CONDITIONS1/4-18 NPTF tap Work area clean and free from blowing dirt andPipe plug dust.Two pipe plugs

MATERIALS/PARTSO-ring (Appendix D, Item 430)

GENERAL SAFETY INSTRUCTIONSPersonnel must be clear from underside and front ofvehicle when engine is running.

Cap and plug set (Appendix C,Item 14)

a. Oil Cooler Pressure Test

CAUTION

Before disconnecting transmission pressure lines, clean surroundingsurfaces and plug all openings to prevent entry of dirt or debris intotransmission. Damage will occur if dirt or debris enters transmission.

1. Disconnect oil cooler supply hose (1) from elbow (2) on top of oil cooler (7).

NOTENote elbow alignment for connection.

2. Loosen nut (3) and remove elbow (2) and O-ring (4) from oil cooler (7). Discard O-ring (4).3. Using drill press and 21/64 drill bit, drill hole in side of elbow (2) opposite hose port.4. Tap hole in elbow (2) with 1/4-18 NPTF tap.

CAUTION

After tapping, elbow must be thoroughly cleaned and all burrsand shavings removed. Any shavings entering system will damagetransmission.

5. Remove elbow (2) from drill press and thoroughly clean.

6. Install new O-ring (4) and elbow (2) in oil cooler (7) until aligned as noted in step 2.7. Tighten nut (3) until O-ring (4) is seated.

8. Install pipe plug (8) on elbow (2).9. Connect oil cooler supply hose (1) to elbow (2).

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TM 9-2320-272-24-4

5-60. TRANSMISSION OIL PRESSURE TESTING (Contd)

10. Remove oil sampling valve (6) from elbow (5).11. Install pressure gauge and gauge hose (9) on elbow (5).

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TM 9-2320-272-24-4


NOTERefer to TM 9-2320-272-10 when performing steps 12 through 20.

12. Set parking brake.

WARNING

Ensure all personnel are clear from underside and front of vehiclebefore starting engine. Transmission slipping into gear may causeinjury to personnel.

13. Start engine and check oil cooler connections for leaks.CAUTION

Do not maintain stalled condition for longer than 30-secondintervals. Transmission oil may overheat and cause transmissiondamage.

14. Place transmission shift lever in 1-5 (drive) and operate engine at 1,200 rpm.15. Place transmission shift lever in N (neutral) and operate engine at normal operating temperature.16. Check transmission oil level.17. Operate engine at 1,650 rpm with transmission shift lever in N (neutral) and parking brake set.

Check pressure gauge and note reading.

18. If pressure is less than 26 psi (179.2 kPa), check for hose or internal oil cooler leakage.19. If pressure exceeds 26 psi (179.2 kPa), check for cooler, cooler filter, or cooler hose restriction.

20. Stop engine and disconnect gauge and hose (2) from elbow (1).21. Install oil sampling valve (3) in elbow (1).22. Remove pipe plug (5) from supply hose elbow (4).23. Install pressure gauge and hose (2) in supply hose elbow (4).

WARNING

Ensure all personnel are clear from underside and front of vehiclebefore starting engine. Transmission slipping into gear may causeinjury to personnel.

NOTERefer to TM 9-2320-272-10 when performing steps 24 through 29.

24. Set parking brake.

25. Start engine and check oil cooler connections for leaks.26. Operate engine at 1,650 rpm with transmission shift lever in N (neutral) and parking brake set.

Check pressure gauge and note reading.27. If pressure is below 30 psi (207 kPa), check for hose or internal oil cooler leakage.28. If pressure exceeds 50 psi (345 kPa), check for cooler or cooler hose restriction.29. Stop engine and disconnect gauge and hose (2) from supply hose elbow (4).30. Install pipe plug (5) in elbow (4).

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TM 9-2320-272-24-4


5-389

TM 9-2320-272-24-4


b. Main Pressure and Governor Pressure Test

1.

2.

3.4.

5.

6.

7.

8.

9.

10.

11.12.

13.

14.

WARNING

Ensure transmission-to-transfer case propeller shaft has beenremoved before performing this test. If test is performed withpropeller shaft installed, wheel blocks (chocks) will not preventvehicle from rolling and causing injury to personnel.

Remove transmission-to-transfer case propeller shaft (para. 3-148).CAUTION

Before disconnecting transmission pressure lines, clean surroundingsurfaces and plug all openings to prevent entry of dirt or debris intotransmission. Damage will occur if dirt or debris enters transmission.

NOTETransmission-to-transfer case propeller shaft removal allowstransmission output shaft to rotate to build up governor oilpressure. Upshift will not occur without governor pressure.

Have drainage container ready to catch oil.Disconnect main pressure line (1) from adapters (2) and (5) and remove main pressure line (1).Remove adapter (5) from main pressure port (6).Disconnect governor pressure line (4) from adapters (3) and (9) and remove governor pressure line (4).

NOTEOnly M936/A1/A2 vehicles are equipped with check valve.

Remove adapter (9) and check valve (8) from transmission auxiliary governor pressure port (7).Install 1/8-27 NPTF Thd pipe plug (13) in auxiliary governor pressure port (7).

Connect pressure gauge and hose (12) to main pressure port (6) with 1/8-27 NPTF Thd hosefitting (11).

NOTERefer to TM 9-2320-272-10 for steps 8 through 28.

Start engine, check pressure port connections for leaks, and check oil.

Operate engine at 625 ± 25 rpm with transmission (10) shift lever in N (neutral) and parking brakeset.

Note pressure reading on pressure gauge. If pressure is not 125 psi (802 kPa), repair trans-mission (10) as necessary.

NOTEDo not maintain stalled condition for longer than 30-secondintervals. Transmission oil may overheat and cause transmissiondamage.

Place transmission shift lever in 1-5 (drive) position.Operate engine at 1,200 ± 25 rpm and note pressure reading on pressure gauge. If pressure is not180-205 psi (1,241-1,413 kPa), repair transmission (10) as necessary.

Stop engine and place transmission shift lever in N (neutral).

Disconnect pressure gauge and hose (12) from main pressure port (6) on left side oftransmission (10).

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TM 9-2320-272-24-4


5-391

TM 9-2320-272-24-4


15. Remove pipe plug (4) from auxiliary governor pressure port (3) and install in main pressure port (5).16. Install pressure gauge and hose (2) in auxiliary governor pressure port (3).17. Start engine and check pressure port connection for leaks.

18. Check transmission oil level.19. Place transmission shift lever in 1-5 (drive) position and operate engine at 1,650 rpm. Note reading

on pressure gauge.20. If pressure is not 82-91 psi (565-627 kPa), repair transmission (1) as necessary21. Stop engine and disconnect pressure gauge and hose (2) from auxiliary governor pressure port (3).22. Remove pipe plug (4) from main pressure port (5).

NOTEOnly M936/A1/A2 vehicles are equipped with check valve.

23. Install check valve (8) and adapter (9) in auxiliary governor pressure port (3). Ensure bleed hole endof check valve (8) is inserted into pressure port (3) first.

24. Install governor pressure line (10) on adapters (9) and (12).

25. Install adapter (7) in main pressure port (5).26. Install main pressure line (6) on adapters (7) and (11).27. Start engine and check pressure port connections for leaks.28. Check transmission oil level.29. Install transmission-to-transfer case propeller shaft (para. 3-148).

c. Automatic Shift Speed Test

1. Road test vehicle and record engine rpm at shift points (TM 9-2320-272-10).2. With vehicle in operation, shift transmission through the range sequence. See table 5-17 for lever

range sequence.3. Check recorded engine shift point rpm with table 5-17.4. If shift points are incorrect, check modulator adjustment (para. 5-61). If modulator adjustment does

not correct shift speed, repair transmission (1) as necessary.

Table 5-17. Transmission Shift Point Check.

SELECTORLEVER RANGE

1-2

1-31-4

1-5 (drive)

THROTTLE

Fully open

AUTOMATIC ENGINESHIFTING (RPM)

1-2 1,900-2,0502-2 1,900-2,050 (before converter lock-in)

2-2 1,600-1,825 (after converter lock-in)

2-3 2,000-2,150

3-4 2,030-2,140

4-5 2,015-2,130

5-392

5-60. TRANSMISSION

TM 9-2320-272-24-4

5 -393

5-61. TRANSMISSION

TM 9-2320-272-24-4

THIS TASK COVERS:

a . Tes t ing b. Adjus tment

INITIAL SETUP:


TOOLS

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Vehicle at curb weight (empty) (TM 9-2320-272-10).

General mechanic’s tool kit (Appendix E, Item 1) SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TM)Dry conditions, open roads, and easy grades.

LO 9-2320-272-12TM 9-2320-272-10TM 9-2320-272-24P

NOTEVehicle engine must be at normal operating temperature of 175-195°F (79-90°C) as indicated by temperature gauge. Transmissionoil temperature must be at normal operating temperature of 120-220°F (49-104°C) as indicated by temperature gauge.

Refer to TM 9-2320-272-10 for steps 1 through 7.

1. Allow vehicle engine and transmission to reach normal operating temperatures with transmissionshift lever in N (neutral) and parking brake set.

2. After warmup, depress accelerator pedal until engine reaches 2,100 rpm. If engine does not reach2,100 r-pm, see table 4-1, fuel system malfunction 15. Proceed with testing if engine reaches2,100 rpm.

NOTEAssistant will operate vehicle as directed by mechanic. Mechanicwill observe and record engine rpm indicated by tachometerduring shift changes.

3. Place transmission shift lever in 1-2 (second) and road test vehicle.

4. Accelerate at full throttle, 1,900-2,050 rpm, and note shift change. Record engine rpm at moment ofshift change.

5. Stop vehicle and repeat steps 3 and 4 in 1-3 (third).

6. Stop vehicle and repeat steps 3 and 4 in 1-4 (fourth).7. Stop vehicle and repeat steps 3 and 4 in 1-5 (drive).

8. Compare recorded engine rpm at shift points with correct shift point ranges given in table 5-17. Ifall shift points are too high or too low by approximately same amount, adjust modulator (4).

1. Inspect modulator (4) and cable (3) for looseness and improper installation.

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5-61. TRANSMISSION

TM 9-2320-272-24-4

NOTEModulator will be adjusted if properly installed. Refer topara. 3-145 for correct modulator and cable installation andadjustment instructions.

2. If looseness and/or improper installation are found, correct and retest modulator (4) and cable (3).3. Remove modulator link (2) from throttle lever (1) and reinstall modulator link (2).

4. Retest modulator (4). If retest indicates defective modulation, replace modulator (4).

FOLLOW-ON TASKS: Fill transmission to proper oil level (LO 9-2320-272-12).Start engine (TM 9-2320-272-10) and road test vehicle.

5-395

5-62. TRANSMISSION

TM 9-2320-272-24-4

THIS TASK COVERS:

Forward Stall Test

INITIAL SETUP:


TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)

REFERENCES (TM)LO 9-2320-272-12TM 9-2320-272-10TM 9-2320-272-24P

EQUIPMENT CONDITION• Parking brake set (TM 9-2320-272-10).• Wheels blocked (chocked) (TM 9-2320-272-10).


GENERAL SAFETY INSTRUCTIONSDo not allow anyone to stand in front of vehiclewhen conducting a stall test.

WARNING

Do not allow anyone to stand in front of vehicle when conductingstall test. Vehicle movement may cause injury to personnel.

CAUTION

• Do not maintain the stalled condition longer than 30-secondintervals due to rapid heating of transmission oil. Observetransmission oil temperature gauge. Normal operating rangeis 120-220°F (49-104°C).

• Observe engine coolant temperature gauge. Operating tempera-ture is 175-195°F (79-90°C).

• If oil temperature reaches 300°F (148°C), or if thirty seconds isinsufficient time to complete needed tests, transmission oiltemperature must be lowered or damage to transmission mayresult.

• Run engine at 1,200-1,500 rpm with transmission in neutral fortwo minutes to cool oil between tests.

NOTE• The stall test is conducted when engine and/or transmission are

not performing satisfactorily The purpose of the stall test is todetermine if transmission or engine is the malfunctioning unit.

• The vehicle’s transmission will stay in first speed during thestall tests regardless of transmission 5-4-3-2 and 1 quadrantposition. Transmission does not and cannot upshift because theinternal mechanism, output shaft, and governor are notturning. The stall test checks the engine performance, converterclutch operation or installation, and holding ability of theconverter one-way clutch.

• Refer to TM 9-2320-272-10 for the following steps.

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5-62. TRANSMISSION

TM 9-2320-272-24-4

1.2.

3.

4.

5.

Apply service brakes and place transmission shift lever in any forward drive position 5-4-3-2-1.Accelerate engine to full throttle (1,900-2,050 rpm).

NOTEPerform step 3 only if engine speed exceeds 1,700 rpm.

If engine speed exceeds 1,700 rpm, check transmission oil level.a. If oil level is low, fill to proper level.

b. If oil level is correct, repair transmission as necessary.NOTE

Perform steps 4 and 5 only if engine speed is less than1,900 rpm.

Refer to table 4-1, Mechanical Troubleshooting.

If engine speed is less than 1,400 rpm, troubleshoot engine for loss of power.

If engine is performing satisfactorily, repair transmission torque converter (para. 5-41).

FOLLOW-ON TASK: Start engine (TM 9-2320-272-10) and road test vehicle.

TM 9-2320-272-24-4

Section IV. TRANSFER CASE MAINTENANCE

THIS TASK COVERS:


c. Assembly and Adjustment

INITIAL SETUP:


SPECIAL TOOLSCrowfoot wrench (Appendix E, Item 163)Two flange puller standoffs

(Appendix F, Item 1)

TOOLSGeneral mechanic’s tool kit (Appendix E. Item 1)Mechanical puller (Appendix E, Item 102)Torque wrench (Appendix E, Item 144)Outside micrometer (Appendix E, Item 80)Dial indicator (Appendix E, Item 36)Arbor pressFeeler gaugePrybarSoft-faced hammerTorque multiplier

MATERIALS/PARTSCylinder assembly (Appendix D, Item 92)Seal (Appendix D, Item 254)Three seals (Appendix D, Item 500)Three locknuts Appendix D, Item 320)Snapring Appendix D, Item 663)Woodruff key (Appendix D, Item 727)Two seals (Appendix D, Item 627)Adhesive sealant (Appendix C, Item 4)GAA grease (Appendix C, Item 28)Gasket sealant (Appendix C, Item 30)Lubricating oil (Appendix C, Item 47)Sealing compound (Appendix C, Item 62)

PERSONNEL REQUIRED

TWO

REFERENCES (TM)TM 9-2320-272-24PTM 9-214

EQUIPMENT CONDITIONTransfer case removed (para. 4-94 or para. 4-95).

GENERAL SAFETY INSTRUCTIONSSupport transfer case with wood blocks beforeperforming disassembly.

WARNING

Transfer case is heavy. Use wood blocks to prevent transfer casefrom tipping over and causing injury to personnel.

NOTEClean exterior of transfer case thoroughly before performingprocedure.

1. Using crowfoot wrench, remove interlock air cylinder (1) and push rod (2) from transfer case (3).

2. Remove eight screws (5) and inspection cover (4) from transfer case (3).

3. Remove locknut (6) and washer (7) from output shaft (14). Discard locknut (6).

4. Using mechanical puller, remove output flange (8) and parking brake drum (9) from outputshaft (14).

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5. Remove actuating plate (10) from brakeshoe backing plate (11).6. Remove four screws (16), dustcover (12), and brakeshoe assembly (15) from companion flange (13).

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7. Disconnect oil line (4) from elbows (3) and (5).

8. Remove elbow (3) from oil pump (2).NOTE

Perform steps 9 and 10 for vehicles equipped with transfer casepower takeoff (PTO).

9. Disconnect oil line (9) from elbows (5) and (8).

10. Remove elbow (8) from PTO (10).11. Remove elbow (5), adapter (6), and filter screen (7) from transfer case (1). Clean filter screen (7).

NOTEMark position of oil pump for installation.

12. Remove six screws (13), washers (12), and oil pump (11) from transfer case (1).13. Bend tabs of locking plates (15) away from screws (16).

14. Remove four screws (16), locking plates (15), cover (14), cylinder (18), piston (19), and gasket (21)from transfer case (1) and declutch shaft (22). Discard gasket (21), piston (19), cylinder (18), andlocking plates (15).

15. Remove seals (17) and (20) from cover (14) and piston (19). Discard seals (17) and (20).

WITHOUT TRANSFER CASE PTO

5-400

5-63. TRANSFER

TM 9-2320-272-24-4

WITH TRANSFER CASE PTO

TM 9-2320-272-24-4

NOTEChain is necessary to prevent main and output flanges fromrotating when removing hardware.

Tag main and front output flanges for installation.

16. Install chain on main flange (5) and output flange (11) with two washers (9), screw (10), twowashers (3), screw (2), and nut (4).

17. Remove locknut (8) and washer (7) from main input shaft (6). Discard locknut (8).

18. Remove locknut (1) and washer (13) from front output shaft (12). Discard locknut (1).

19. Remove screw (10), two washers (9), nut (4), washer (3), screw (2), washer (3), and chain from mainflange (5) and output flange (11).

20. Using puller, remove main flange (5) and output flange (11) from main input shaft (6) and frontoutput shaft (12).

NOTEPerform steps 21 and 22 for vehicles equipped with PTO.

21. Remove six screws (15), washers (16), and PTO (14) from transfer case (17).22. Remove setscrew (19), PTO drive gear (18). and seal (20) from main input shaft (6). Discard

seal (20).

5-402

5-63. TRANSFER

TM 9-2320-272-24-4

WITH TRANSFER CASE PTO

5-403

5-63. TRANSFER

TM 9-2320-272-24-4

23. Loosen setscrew (13) and remove collar (12), seal (ll), and baffle (10) from main input shaft (7).Discard seal (11).

24. Remove seven screws (20), washers (19), flange (3), and shim pack (4) from transfer case (5).

25. Remove slinger (1) and seal (2) from flange (3). Discard seal (2).

26. Remove four screws (17), washers (18), two screws (16), washers (15), and gear cover (14) fromtransfer case (5).

27. Remove nineteen screws (9) and washers (8) from transfer case cover (21).28. Position puller on transfer case cover (21) with drive screw of puller over intermediate shaft (7) and

two long screws through puller and into transfer case cover (21).

29. Remove transfer case cover (21) from transfer case housing (22).

5-404

TM 9-2320-272-24-4

30. Remove setscrew (24), hi-lo shift fork (23), and hi-lo shift shaft (25) from synchronizer gear (26) andtransfer case housing (22).

31. Remove main input shaft (7), rear output shaft (28), and intermediate shaft (27) from bearingraces (29) and transfer case housing (22).

32. Remove setscrew (32), declutch shaft (34), declutch fork (31), sliding clutch (30), and spring (33)from transfer case housing (22). Discard spring (33) if broken or distorted.

5-405

5-63. TRANSFER

TM 9-2320-272-24-4

33. Remove hi-lo shaft seal (2) from transfer case housing (1). Discard seal (2).

34. Remove six screws (6), washers (5), main input shaft cover (4), and shim pack (3) from transfercase housing (1).

35. Remove seal (7) from main input shaft cover (4). Discard seal (7).36. Remove plug (12) from intermediate shaft cover (9).37. Remove six screws (11), washers (10), intermediate shaft cover (9), and shim pack (8) from transfer

case housing (1).38. Remove six screws (14), washers (15), and front output shaft cover (16) from transfer case

housing (1).39. Remove seal (13) from front output shaft cover (16). Discard seal (13).

40. Remove front output shaft (17) from transfer case housing (1).

NOTEWhen disassembling front output, rear output, and intermediateshafts, tag all bearings, spacers, and gears for installation.

41. Using flat-axle type bearing puller, remove front output shaft bearing (18) from front outputshaft (17).

42. Remove snapring (19) from front output shaft bearing (18).

43. Remove spacer (24) from rear output shaft (21).44. Using arbor press, remove rear output shaft bearings (20) and (23), and gear (22) from rear output

shaft (21).

5-406

5-63. TRANSFER

TM 9-2320-272-24-4

5-407

5-63. TRANSFER

TM 9-2320-272-24-4

45.

46.

47.

48.

49.

50.

Remove snapring (8), speedometer drive gear (7), and woodruff key (4) from intermediate shaft (3).Discard woodruff key (4) and snapring (8).

Using arbor press, remove intermediate bearing (6), intermediate high-speed gear (5), intermediatebearing (1), and intermediate low-speed gear (2) from intermediate shaft (3).Remove companion flange spacer (9) from main input shaft (14).Using arbor press, remove main input shaft bearing (16), bearing spacer (17), and high-speedgear (18) from main input shaft (14).

Remove high-speed gear spacer (19) and synchronizer gear (20) from main input shaft (14).

Using arbor press, remove main input shaft bearing (10), bearing spacer (11), low-speed gear (12),and low-speed gear spacer (13) from main input shaft (14).


3. Inspect two dowel pins (15) of main input shaft (14) for breaks. If broken, replace dowel pins (15).

5-408

5-63. TRANSFER5-63. TRANSFER

TM 9-2320-272-24-4

5-409

TM 9-2320-272-24-4

4. Inspect three dowel pins (2) for bends and breaks. Replace dowel pins (2) if bent or broken.5. Remove filler plug (5) and drainplug (6) from transfer case housing (8) and inspect for stripped

threads. Replace plugs (5) or (6) if threads are stripped.6. Inspect freeze plugs (7) and (9) for looseness. Replace freeze plugs (7) or (9) if loose.

7. Inspect transfer case cover (3) and housing (8) for breaks, cracks, and stripped threads. Replacetransfer case cover (3) or housing (8) if broken, cracked, or threads are not repairable (para. 2-5).

NOTETransfer case housing and cover bearings and bearing races arematched parts and must be replaced as a set.

Perform steps 9 and 10 if bearings or bearing races failinspection.

8. Inspect bearings (4) and bearing races (1) in accordance with TM 9-214. If damaged, replacebearing (4) and matched bearing race (1).

9. Remove bearing race (1) from transfer case housing (8) or cover (3) by tapping alternately aroundouter edge of bearing race (1). Discard bearing race (1).

10. Using arbor press, install new bearing race (1) on transfer case housing (8) or cover (3).

5-410

5-63. TRANSFER

TM 9-2320-272-24-4

5-411

TM 9-2320-272-24-4

1.

2.

3.4.

5.

6.7.8.

9.

10.

11.

12.13.14.

NOTEPrior to assembly, apply coat of oil to lubricate all gears, bearings,and shafts.

Measure thickness of bearing spacer (3). Replace bearing spacer (3) if thickness is less than0.265 in. (6.73 mm).

Install low-speed gear spacer (5), low-speed gear (4), and bearing spacer (3) on main input shaft (6).Ensure low-speed gear spacer (5) is aligned on dowel pin (8).Using arbor press, install main input shaft bearing (2) on main input shaft (6).Measure thickness of bearing spacer (10). Replace bearing spacer (10) if thickness is less than0.143 in. (3.63 mm).

Install synchronizer gear (13), high-speed gear spacer (12), high-speed gear (11), and bearing spacer (10) on main input shaft (6). Ensure gear spacer (12) is aligned with dowel pin (7).

Using arbor press, install main input shaft bearing (9) on main input shaft (6).Install companion flange spacer (1) on main input shaft (6).Using arbor press, install intermediate low-speed gear (15) and intermediate hearing (14) onintermediate shaft (16).Install intermediate high-speed gear (18) and roller bearing (21) on intermediate shaft (16).

Install new woodruff key (17) and speedometer gear (20) on intermediate shaft (16) with newsnapring (19).

Using arbor press, install rear output shaft driven gear (24) and rear output shaft bearings (25)and (22) on rear output shaft (23).Install rear output shaft spacer (26) on rear output shaft (23).Using arbor press, install front output shaft bearing (28) on front output shaft (27).Install snapring (29) on front output shaft bearing (27).

5-412

5-63. TRANSFER

TM 9-2320-272-24-4

5-413

5-63. TRANSFER

TM 9-2320-272-24-4

15.

16.

17.

Apply GAA grease to inside diameter of all seals.Install front output shaft (8) in transfer case housing (1) until snapring (9) is flush with transfercase housing (1).

Install new front output shaft seal (4) in front output shaft cover (7).

Apply a thin coating of gasket sealer to mating surfaces of front output shaft cover (7) and transfercase housing (1).

18.

19.20.21.

22.

23.24.

Install front output shaft cover (7) on transfer case housing (1) with six washers (6) and screws (5).Tighten screws (5) 40-65 lb-R (54-88 N•m).Install new input shaft seal (3) on main input shaft cover (2).Install sliding clutch (10) on front output shaft (8).Position declutch fork (11) on sliding clutch (10).

Position declutch spring (13) under declutch fork (11) and insert declutch shaft (14) throughdeclutch fork (11), declutch spring (13), and into transfer case housing (1).

Install declutch fork (11) on declutch shaft (14) with setscrew (12).Install intermediate shaft (15), rear output shaft (16), and main input shaft (18) in three bearingraces (17) on transfer case housing (1).

25. Position hi-lo shift fork (19) on synchronizer gear (22).26. Insert hi-lo shift shaft (21) through hi-lo shift fork (19) and into transfer case housing (1).27. Install hi-lo shift fork (19) on hi-lo shift shaft (21) with setscrew (20).

NOTE

5-414

5-63. TRANSFER

TM 9-2320-272-24-4

5-415

5-63. TRANSFER

TM 9-2320-272-24-4

28. Apply gasket sealant to mating surfaces of transfer case cover (1) and housing (5).

29. Install three dowel pins (2) on transfer case cover (1).

30. Align dowel pins (2) on transfer case cover (1) with holes in transfer case housing (5) and installtransfer case cover (1) on transfer case housing (5) with nineteen washers (4) and screws (3).Tighten screws (3) 40-65 lb-ft (54-88 N•m).

31. Tap around outer edge of bearing race (8) to seat against main input shaft bearing (9).

32. Install baffle (7) on main input shaft (6).

NOTEPerform steps 32 through 34 for vehicles equipped with PTO.

33. Apply adhesive sealant to setscrew (11).

34. Install new seal (12) and PTO drive gear (10) on recess of main input shaft (9) with setscrew (11).Tighten setscrew (11) 12-16 lb-ft (16-22 N•m).

35. Apply sealing compound to PTO (16) and transfer case (15) and install PTO (16) on transfercase (15) with six washers (14) and screws (13). Tighten screws (13) 140-65 lb-ft (54-36 N•m).

5-416

5-63. TRANSFER

TM 9-2320-272-24-4

36.37.

38.

Apply adhesive sealant to setscrew (24).Install new seal (23) on retaining collar (25) with large lip toward baffle (7).

Install retaining collar (25) on recess of main input shaft (6) with setscrew (24). Tightensetscrew (24) 12-16 lb-ft (16-22 N•m).

39. Apply a light coating of gasket sealant to mating surfaces of oil pump (26) and transfer case (15).

40.

41.

42.

43.44.

NOTEEnsure to align pump drive with slot on main input shaft.

Install oil pump (26) on transfer case (15) with six washers (18) and screws (17). Tightenscrews (17) 40-65 lb-ft (54-88 N-m).Apply a light coating of gasket sealant to mating surfaces of speedometer drive cover (22) andtransfer case (15).

Install speedometer drive cover (32) on transfer case (15) with six washers (21), four screws (20),and two screws (19). Tighten screws (19) and (20) 40-65 lb-ft (54-88) N•m).

Install new seal (28) and slinger (27) on flange (29).Apply gasket sealant to new hi-lo shift shaft seal (30) and install on transfer case (15).

5-417

5-63. TRANSFER

TM 9-2320-272-24-4

NOTEStep 45 establishes initial shim pack thickness for intermediateshaft.

45. Install intermediate shaft cover (2) on transfer case (1) and tap alternately around outer edge withsoft-faced hammer.

46. Using feeler gauge, measure and record clearance between intermediate shaft cover (2) andtransfer case (1).

47. Remove intermediate shaft cover (2) from transfer case (1).

NOTEUse measurement from step 46 plus a .003 in. (.7692 mm) shim forinitial shim pack thickness.

48. Install shim pack (3) and intermediate shaft cover (2) on transfer case (1) with six washers (4) andscrews (5). Tighten screws (5) 40-65 lb-ft (54-88 N•m).

49. Mount dial indicator on transfer case (1) with tip of plunger positioned through hole in intermediateshaft cover (2) on intermediate shaft (6).

NOTEPerform step 50 to ensure intermediate shaft will rotate freelywithout end play.

50. Check intermediate shaft end play as follows:a. Insert prybar through inspection hole (7) and force intermediate shaft (6) to rear of transfer

case (1).b. Set dial indicator to zero.c. Using prybar, force intermediate shaft (6) to front of transfer case (1).d. Record reading from dial indicator and add 0.003-0.006 in. (0.076-0.152 mm) to reading. This

reading will be used for number of shims (3) to be removed.

51. Remove dial indicator from transfer case (1).

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5-63. TRANSFER

TM 9-2320-272-24-4

5 - 4 1 9

5-63. TRANSFER

TM 9-2320-272-24-4

52.

53.

54.

55.

56.

57.

58.

59.

60.

Remove six screws (5), washers (4), intermediate shaft cover (3), and shim pack (2) fromtransfer case (1).

NOTEUse reading obtained in step 50d for number or thickness of shimsto be removed or added for intermediate shaft adjustment.

Remove or add amount of shims (2) as recorded.

CAUTION

Do not apply sealing compound to shims.Apply a sealing compound to lightly coat mating surfaces of transfer case (1) and intermediateshaft cover (3).Install shim pack (2) and intermediate shaft cover (3) on transfer case (1) with six washers (4) andscrews (5). Tighten screws (5) 40-65 lb-ft (54-88 N•m).Install plug (6) on intermediate shaft cover (3). Tighten plug (6) 35 lb-ft 48 N•m)

NOTEStep 57 establishes initial shim pack thickness for main inputshaft.

Install main input shaft cover (7) on transfer case (1) and tap alternately around outer edge withsoft-faced hammer.Using feeler gauge, measure and record clearance between main input shaft cover (7) and transfercase (1).Remove main input shaft cover (7) from transfer case (1).

NOTEUse measurement from step 58 plus a .003 in. .0762 mm) shim forinitial shim pack thickness.

Install shim pack (8) and main input shaft cover (7) on transfer case (1) with six washers (10) andscrews (9). Tighten screws (9) 40-65 lb-ft (54-88 N•m).

5-420

TM 9-2320-272-24-4

5-421

TM 9-2320-272-24-4

61. Mount dial indicator on transfer case (1) with tip of plunger on main input shaft (2).

NOTEPerform steps 62 through 64 to ensure main shaft rotates freelywithout end play.

62. Check main input shaft end play as follows:a. Using prybar through inspection hole (3), force main input shaft (2) to rear of transfer

case (1) and hold.b. Set dial indicator to zero.c. Using prybar through inspection hole (3), force main input shaft (2) to front of transfer

case (1).d. Record reading on dial indicator. End play should be 0.0001-0.005 in. (0.00254-0.127 mm).

63. Remove dial indicator from transfer case (1).64. Remove six screws (7), washers (6), main input shaft cover (5), and shim pack (4) from transfer

case (1).NOTE

Use reading obtained in step 62d for number or thickness of shimsto be removed or added for main input shaft adjustment.

65. Remove or add amount of shims (4) as recorded.CAUTION

Do not apply sealing compound to shims.66. Apply a light coating of sealing compound to mating surfaces of transfer case (1) and main input

shaft cover (5).67. Install shim pack (4) and main input shaft cover (5) on transfer case (1) with six washers (6) and

screws (7). Tighten screws (7) 40-65 lb-ft (54-88 N•m).

5-422

TM 9-2320-272-24-4

5-423

5-63. TRANSFER

TM 9-2320-272-24-4

NOTESteps 68 and 69 establish initial shim pack thickness for rearoutput shaft.

68. Install companion flange (2) on transfer case (1) and tap alternately around outer edge with soft-faced hammer.

69. Using feeler gauge, measure and record clearance between companion flange (2) and transfercase (1).

70. Remove companion flange (2) from transfer case (1).NOTE

Use measurement from step 69 plus a 0.003 in. (0.0762 mm) shimfor initial shim pack thickness.

71. Install shim pack (3) and companion flange (2) on transfer case (1) with seven washers (4) andscrews (5). Tighten screws (5) 60-100 lb-ft (81-136 N-m).

72. Mount dial indicator on transfer case (1) with tip of plunger positioned on rear output shaft (6).

73. Check rear output shaft (6) end play as follows:a. Using prybar through inspection hole (7), force rear output shaft (6) to front of transfer

case (1) and hold.b. Set dial indicator to zero.c. Using prybar through inspection hole (7), force rear output shaft (6) to rear of transfer

case (1).d. Record reading on dial indicator. End play should be 0.0001-0.005 in. (0.00254-0.127 mm).

74. Remove dial indicator from transfer case (1).

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TM 9-2320-272-24-4

5-425

5-63. TRANSFER

TM 9-2320-272-24-4

75. Remove seven screws (4), washers (3), and companion flange (5) from transfer case (1).

NOTEUse reading obtained in step 73d for number or thickness of shimsto be removed or added for rear output shaft adjustment.

76. Remove or add amount of shims (2) as recorded.

CAUTION

Do not apply sealing compound to shims.77. Apply a light coating of sealing compound to mating surfaces of transfer case (1) and companion

flange (5).78. Install shim pack (2) and companion flange (5) on transfer case (1) with seven washers (3) and

screws (4). Tighten screws (4) 110-145 lb-ft (149-197 N•m).

NOTEApply GAA grease to inside diameter of all seals.

79. Install main input flange (6) on main input shaft (9).80. Install front output flange (7) on front output shaft (8).

NOTEChain is necessary to prevent main and output flanges fromrotating when removing hardware.

81. Install chain on main input flange (6) with two washers (16) and screw (17).82. Install chain on front output flange (7) with washer (12), screw (11), washer (12), and nut (13).83. Apply a thin coating of gasket sealant to mating surfaces of washers (18) and (14), and install

washers (18) and (14) and new locknuts (10) and (15) on front output shaft (8) and main inputshaft (9). Tighten locknuts (10) and (15) 450-600 lb-ft (610-814 N•m).

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5-427

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TM 9-2320-272-24-4

84.

85.

86.

87.

88.

89.

90.91.

92.

Install filter screen (3), adapter fitting (4), and elbow (5) on transfer case (2). Tighten elbow (5)15 lb-ft (20 N•m).

NOTEPerform steps 85 and 86 for vehicles equipped with PTO.

Install elbow (1) on PTO (7). Tighten elbow (1) 26 lb-ft (35 N•m).

Connect oil line (6) to elbows (5) and (1).

Install nipple end of elbow (13) on oil pump (8). Tighten elbow (13) 20 lb-ft (27 N•m).

Connect oil line (14) to elbows (5) and (13).

Install new seal (9) on cover (12).Install new seal (17) on piston (16).Install new gasket (18). new piston (16), new cylinder (15), and cover (12) on transfer case (2) withfour new locking plates (11) and screws (10). Tighten screws (10) 5-10 lb-ft (8-13 N•m).Bend tabs of locking plates (11) over heads of screws (10).

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TM 9-2320-272-24-4

5-429

5-63.

TM 9-2320-272-24-4

93.

94.

95.96.

97.

98.

99.

Install brakeshoe assembly (12) and dust cover (9) on companion flange (10) with fourscrews (13). Tighten screws (13) 180-230 lb-ft (244-312 N•m).

Position actuating plate (6) against backing plate (7) so retainer opening (5) fits over brake leverstud (8) of backing plate (7).

NOTEApply GAA grease to inside diameter of all seals.

Install parking brake drum (4) and output flange (3) on output shaft (11).Apply a thin coating of gasket sealant to mating surfaces of washer (2) and install washer (2) andnew locknut (1) on output shaft (11). Tighten locknut (1) 450-600 lb-ft (610-814 N•m).Remove nut (18), washer (17), screw (16), washer (17), screw (14), washer (19), and chain from maininput flange (20) and front output flange (15).

Apply a thin coating of gasket sealant to mating surfaces of inspection plate (24) and transfercase (23) and install inspection plate (24) on transfer case (23) with eight screws (25). Do not tightenscrews (25).Using crowfoot wrench, install pushrod (22) and interlock air cylinder (21) on transfer case (23).Tighten interlock air cylinder (21) 30-40 lb-ft (41-54 N•m).

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TM 9-2320-272-24-4

FOLLOW-ON TASK: Install transfer case (para. 4-94 or para. 4-95).

5-431

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

Section V. FRONT AND REAR AXLE MAINTENANCE

THIS TASK COVERS:

a. Disassembly c. Assembly and Adjustmentb. Cleaning, Inspection, and Repair

INITIAL SETUP:


SPECIAL TOOLSBearing replacer (Appendix E, Item 14)Two puller screws (Appendix E, Item 104)

TOOLSGeneral mechanic’s tool kit

(Appendix E, Item 1)Mechanical puller kit (Appendix E, Item 102)Inside micrometer

(Appendix E, Item 83)Torque wrench (Appendix E, Item 146)Torque wrench (Appendix E, Item 145)Dial indicator (Appendix E, Item 36)Outside micrometer (Appendix E, Item 80)Arbor pressTorque multiplierViseSoft-head hammerChainLifting deviceBearing preload tester

MATERIALS/PARTSGasket (Appendix D, Item 206)Gasket (Appendix D, Item 207)Gasket (Appendix D, Item 208)Three safety wires, 12 in. (Appendix D, Item 568)Wear sleeve kit (Appendix D, Item 717)Gasket and shim set (Appendix D, Item 248)Six lockwashers (Appendix D, Item 350)Locktab washer (Appendix D, Item 344)Two cotter pins (Appendix D, Item 61)Two oil seals (Appendix D, Item 500)Gasket (Appendix D, Item 653)Six lockwashers (Appendix D, Item 354)Safety wire, 36 in. (Appendix D, Item 568)Crocus cloth (Appendix C, Item 20)GAA grease (Appendix C, Item 28)Lubricating oil (Appendix C, Item 47)Blue oil-base pigment (Appendix C, Item 54)Sealing compound (Appendix C, Item 61)Sealing compound (Appendix C, Item 62)Twine (Appendix C, Item 77)White carbonate pigment (Appendix C, Item 78)

REFERENCES (TM)LO 9-2320-272-12TM 9-214TM 9-2320-272-24P

EQUIPMENT CONDITIONDifferential and carrier assembly removed(para. 4-100).

NOTEFront and rear differentials are repaired the same way.

1. Remove safety wires (1) from two screws (2) and four screws (4). Discard safety wires (1).

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2. Remove two screws (2) and adjusting nut locks (3) from bearing caps (6).CAUTION

Scribe bearing caps and saddles for installation. These items aremachine-matched and damage will result if they are intermixed.

3. Remove four screws (4), washers (5), and two bearing caps (6) from differential carrier housing (11).NOTE

Tag bearings and races as matched parts for inspection andinstallation.

4. Remove two adjusting nuts (9) and bearing races (8) from bearing saddles (10) and caps (6).5. Remove differential gear assembly (7) from differential carrier housing (11) and bearing

saddles (10).

6. Using puller, remove two tapered roller bearings (12) from differential housings (13).7. Remove safety wire (18) from eight slotted nuts (19). Discard safety wire (18).

CAUTION

Two gear housings and helical drive gear must be scribed forinstallation. These items are machine-matched and damage mayresult if they are intermixed.

8. Remove eight slotted nuts (19) and screws (22) from two differential housings (13). Mark twodifferential housings (13) and helical ring gear (16) for installation.

9. Remove four bevel spider gears (20), thrust washers (21), and spider (17) from differentialhousing (13).

10. Remove two bevel side gears (15) and thrust washers (14) from differential housings (13).

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11.

12.

13.

14.15.

16.

17.

Remove two cotter pins (l), nuts (2), and companion flanges (3) from mainshaft (4). Discard cotterpins (1).Remove six screws (9) and lockwashers (10) from rear bearing cover (8). Discard lockwashers (10).

Remove rear bearing cover (8), gasket (6), and thrust washer (5) from differential carrierhousing (11). Discard gasket (6).Remove oil seal (7) from rear bearing cover (8). Discard oil seal (7).

Remove eight screws (16) and washers (17) from front bearing cover (13).

Remove front bearing cover (15) and gasket (12) from differential carrier housing (11). Discardgasket (12).

Using puller, remove oil seal (13) and gasket (14) from front bearing cover (15). Discard oil seal (13)and gasket (14).

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18. Remove mainshaft and pinion gear assembly (4) from differential carrier housing (11).

NOTE

19.

20.21.22.

23.

Tag and retain shims for measurement and installation.

Using bearing remover, remove shims (19) from front of differential carrier housing (11).

Remove bearing (18) from rear of differential carrier housing (11).

Place mainshaft (4) in soft-jawed vise.

Using puller, remove rear bearing race (24) from rear of mainshaft (4).Open tab(s) on locktab washer (21) and remove outer nut (20), locktab washer (21), keywasher (22),and inner nut (23) from mainshaft (4). Discard locktab washer (21).

5 - 4 3 5

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24.

25.26.27.28.

NOTEBearings and races are matched sets and must be kept togetherfor inspection and installation.

Using arbor press, remove outer bearing (1), retainer (3), and spacer (5) from pinion gear (6) andmainshaft (7).

NOTERaces may require light tapping to remove from retainer.

Using bearing replacer, remove races (2) and (4) from retainer (3).Remove mainshaft (7) from vise.Using arbor press, remove pinion gear (6) with bearing (8) from mainshaft (7).Using puller, remove bearing (8) from pinion gear (6).

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29.

30.31.

32.

33.

34.

35.

36.37.

Remove eight screws (9) and washers (10) from side cover (11).

Remove side cover (11) and gasket (12) from differential carrier housing (13). Discard gasket (12).Remove six screws (17) and lockwashers (16) from bearing retaining plate (15). Discardlockwashers (16).

NOTERecord number and thickness of shims for installation.

Remove bearing retaining plate (15) and shims (14) from differential carrier housing (13). Discardshims (14).

Remove safety wire (22) from three screws (23) on retaining plate (21). Discard safety wire (22).

Remove three screws (23) and retaining plate (21) from shaft (18).

Install two puller screws (24) in tapped jacking holes (25) in bearing cap (20) and remove bearingcap (20). Tighten screws (24) evenly while removing bearing cap (20). Remove pullerscrews (24) from bearing cap (20).

NOTETag and retain shims for measurement and installation.

Remove shims (19) from differential carrier housing (13).Using arbor press, remove two bearings (27) and races (26) from bearing cap (20).

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38. Remove ten screws (1), washers (5), access cover (2), and gasket (3) from differential carrierhousing (4). Discard gasket (3).

39. Place two soft-iron spacers (10) between bevel ring gear (6) and differential carrier housing (4).

40. Using arbor press, remove helical pinion gear (7) from bevel ring gear (6).

41. Remove spacer (9) and machine key (8) from shaft of helical pinion gear (7).

42. Remove bevel ring gear (6) with bearing (11) from differential carrier housing (4).

43. Remove setscrew (13) from differential carrier housing (4).

CAUTION

Drive bearing sleeve out by tapping evenly. Scoring will occur ifsleeve tilts in housing.

44. Using puller, remove bearing sleeve (12) from differential carrier housing (4).

45. Using puller, remove bearing (11) from bevel ring gear (6).

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1.2.

3.

4.


CAUTION

Differential carrier housing and cap, bearings, and bearing racesare machined or matched parts. Damage may result if they areintermixed. Replace all matched parts as sets if damaged.

Inspect differential carrier housing (14) and bearing caps (16) for scores, cracks, distortion, breaks,burrs, and wear. For repair of minor damage, refer to para. 2-16. Replace housing (14) and caps (16)if either part is damaged.Inspect two adjusting nuts (15) for cracks, breaks, missing locking lugs, and damaged threads.Replace adjusting nut(s) (15) if cracked, broken, locking lugs are missing, or threads are damaged.

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5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

NOTEReplace entire differential gear assembly if helical ring gear,spider, spider gears, bevel gears, or thrust washer fails inspection.

Inspect two bearings (2) and races (1) (TM 9-214). Replace bearing (2) and race (1) as a setif either part fails inspection.Inspect two differential gear housings (4) for chips, burrs, cracks, pitting, scoring, and breaks. Forrepair of minor damage, refer to para. 2-16. Replace entire differential gear assembly if differentialgear housings (4) are damaged.Measure inside diameter of bearing races (5) and outside diameter of differential gear housinghubs (3). The difference between measurements (press fit) must be within 0.0015-0.0035 in.(0.0381-0.0889 mm). Replace entire differential gear assembly if press fit is not within limits.

Inspect four thrust washers (12), bevel spider gears (ll), two thrust washers (6), bevel side gears (7),spider (9), and helical ring gear (8) for cracks, breaks, chips, burrs, scoring, and pitting. For repair ofminor damage, refer to para. 2-16. Replace entire differential gear assembly if any part failsinspection.Measure outside diameter of four spider arms (10). Measurement should be 1.122-1.123 in.(28.50-28.52 mm). Replace entire differential gear assembly if spider arm(s) (10) are not withinlimits.Measure inside diameter of four bevel spider gears (11). Measurement should be 1.128-1.130 in.(28.65-28.70 mm). Replace entire differential gear assembly if bevel spider gear(s) (11) are notwithin limits.

Inspect two bearings (19) and races (18) (TM 9-214). Replace bearing (19) and race (18) asa set if either part fails inspection.Inspect bevel ring gear (13), sleeve (15), spacer (16), and helical pinion gear (17) for chips, breaks,cracks, burrs, nicks, and scores. For repair of minor damage, refer to para. 2-16. Replace bevel ringgear (13), sleeve (15), spacer (16), and helical pinion gear (17) if damaged.

Measure inside diameter of bearing races (20) and outside diameter of pinion gear shaft (21). Thedifference between measurements (press fit) must be within 0.0000-0.0015 in. (0.0000-0.0381 mm).Replace helical pinion gear (17) and bearings(s) (19) if press fit is not within limits.

Inspect bearing (14) (TM 9-214). Replace bearing (14) if damaged.

Measure outside diameter of bevel ring gear (13) and inside diameter of race on bearing (14). Thedifference between measurements (press fit) must be within 0.0006-0.0011 in. (0.015-0.028 mm).Replace bevel ring gear (13) and bearing (14) if press fit is not within limits.Measure outside diameter of bearing (14) and inside diameter of spacer (15). The difference betweenmeasurements (press fit) must be within 0.0030-0.0058 in. (0.076-0.147 mm). Replace bearing (14)and sleeve (15) if press fit is not within limits.

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17.

18.

19.

20.

21.

22.

23.

Inspect two bearings (1) and races (2), bearing (7), and race (6) (TM 9-214). Replacebearings (1) or (7) and appropriate races (2) or (6) if damaged.Inspect bevel pinion gear (3) and mainshaft (4) for chips, burrs, breaks, bends, and scoring. Forrepair of minor damage, refer to para. 2-16. Replace bevel pinion gear (3) or mainshaft (4) ifdamaged.

Measure inside diameter of bearing race (2) and outside diameter of middle step (8) of bevelpinion gear (3). The difference between measurements (press fit) must be within 0.0000-0.0020 in.(0.000-0.051 mm). Replace bearing race (2) and bevel pinion gear (3) if press fit is not within limits.

Measure inside diameter of bearing race (10) and outside diameter of front step (9) of bevelpinion gear (3). The difference between measurements (press fit) must be within 0.0010-0.0025 in.(0.025-0.064 mm). Replace bearing (1) and bevel pinion gear (3) if press fit is not within limits.Measure inside diameter of bearing race (6) and outside diameter of mainshaft shoulder (5). Thedifference between measurements (press fit) must be within 0.0006-0.0019 in. (0.015-0.048 mm).Replace bearing race (6) and mainshaft (40) if press fit is nut within limits.

Measure outside diameter of bearing (6) and inside diameter of rear bore (12) of differential carrierhousing (11). The difference between measurements (press fit) must be +0.0009 to -0.0007 in.(+0.023 to -0.018 mm). Replace bearing (6) and differential carrier housing (11) if press tit is notwithin limits.Inspect companion flange (13), deflector (14), and wear sleeve (15) for cracks, breaks, bends, scoring,and wear. Replace companion flange (13), deflector (14), or wear sleeve (15) if cracked, broken, bent,scored, or worn. Follow instructions in wear sleeve kit, P/N 12375353, for replacement of wearsleeve (15).

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5-64. DIFFERENTIAL AND DIFFERENTIAL CARRIER REPAIR (Contd)

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c. Assembly and Adjustment

1.

2.

3.

4.

5.

6.

7.

NOTECoat all bearings and gears with lubricating oil during reassembly.

Using bearing replacer, install inner bearing race (3) and outer bearing race (1) in retainer (2).Ensure thick edges of races (1) and (3) are toward center of retainer (2).Install bearing (4) on hub of bevel pinion gear (6). Thick inner race (10) must be seated against backedge of teeth (5) on bevel pinion gear (6).

NOTEWhite carbonate pigment is used as a high-pressure lubricant.

Coat long splined end (7) of mainshaft (9) with white carbonate pigment.

Position bevel pinion gear (6) over mainshaft (9), ensuring internal splines in bevel pinion gear (6)align with splined end (7), and press bevel pinion gear (6) and bearing (4) onto mainshaft (9). Noseof bevel pinion gear (6) must seat against shoulder (8).Place mainshaft (7) in soft-jawed vise.

NOTECollar is used to set preload on bevel pinion gear bearings. Ensurecollar removed in disassembly is installed for preload test.

Install spacer (14) on hub (15) of bevel pinion gear (6) next to bearing (16).Position small end (13) of retainer (12) over hub (15) and bearing (161 and place bearing (11) inretainer (12) over hub (15).

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TM 9-2320-272-24-4


8.

9.

10.

11.

12.13.

14.

15.

16.

17.

18.

19.

20.

Install inner nut (4) on threaded portion of hub (5) of bevel pinion gear (7). Ensure stud (9) oninner nut (4) is facing away from retainer (6) and bevel pinion gear (7). Tighten inner nut (4)800-1,000 lb-ft (1,085-1,356 N-m).Install keywasher (3) on hub (5). Ensure hole in keywasher (3) aligns over stud (9) of inner nut (4).

Install new locktab washer (2) on hub (5). Ensure stud (9) sets into a hole in keywasher (3).

Install outer nut (1) on hub (5). Tighten nut (1) 1,OOO-1,200 lb-ft (1,356-1,627 N•m).

NOTEPinion bearings must be preloaded for proper operation ofdifferential assembly.

Wrap twine around retainer (6) and attach to bearing preload tester to determine bearing preload.Observe pointer and pull on bearing preload tester until retainer (6) starts to rotate. Recordreading.If original bearings are installed, bearing preload pull must be 1.2-2.4 lb (0.54-1.09 kg). If torquemethod is used to measure bearing preload, torque must be 4-8 lb-in. (0.5-0.9 N•m).

If new bearings are installed, bearing preload pull must be 3.6-5.5 lb (1.63-2.50 kg). If torquemethod is used to measure bearing preload, torque must be 5-25 lb-in. (0.41-0.62 N•m).

NOTEIf preload is not within given limits, perform steps 16through 19.

If preload is within given limits, go to step 21.

Remove outer nut (1), locktab washer (2), keywasher (3), and inner nut (4) from hub (5) of bevelpinion gear (7).

Using arbor press, remove outer bearing (10), retainer (6), and spacer (11) from hub (5).If preload valve (steps 13, 14, and 15) exceeds limits, use a thicker spacer (11) from bevel piniongear spacer kit. If preload value is less than limits, use a thinner spacer (11).Install parts on hub (5) following steps 5 through 11. Measure bearing preload using either twineand bearing preload tester or torque method. Repeat steps 16 through 19 until bearing preload iswithin limits of either step 14 or 15.Remove mainshaft (8) from soft-jawed vise.

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21. Bend tab(s) (4) on locktab washer over flats on outer nut (1).

22. Using arbor press, install rear bearing inner race (3) on short splined end of mainshaft (2).

23. Using arbor press, install bearing (7) in rear bore (5) of differential carrier housing (6).

24. Install sleeve (8) in bore (13) with notches (10) toward shoulder of bore (13). Ensure hole (9) insleeve (8) aligns with hole (12) in differential carrier housing (6).

25. Install setscrew (11) through hole (12) until seated in sleeve (8).26. Press bearing (15) on hub (20) of bevel ring gear (21). Bearing (15) must rest against shoulder (14)

on hub (20).27. Install spacer washer (16) on keyed end (19) of helical pinion gear (18).

28. Install machine key (17) in keyed end (19) of helical pinion gear (18). Ensure exposed edges ofmachine key (17) are not burred after installation. Remove any burrs with fine mill file.

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29.

30.

Place bevel ring gear (21) in differential carrier housing (6) with hub and bearing (15) pointingtoward bore (22).

Support bevel ring gear (21) with two soft-iron semicircular blocks. Use support adapter (23) as analternate method.

NOTE

31.

32.

White carbonate pigment is used as high-pressure lubricant.

Coat keyed end (19) of helical pinion gear (18) with pigment lubricant and align over bore in bevelring gear (21). Ensure machine key (17) is aligned with keyway in bevel ring gear (21).Using arbor press, install keyed end (19) of helical pinion gear (18) in bore of bevel ring gear (21).

NOTELight tapping with soft-head hammer or use of arbor press may beneeded to install bearing.

33. Remove blocks, turn differential carrier housing (6) over, and push bearing (15) into sleeve (16).

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34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

NOTECoat bearings and races with clean gear oil before installation.

Using bearing replacer, install race (2) in bearing cap (1). Thick edge of race (2) must be towardsmall end (6) of bearing cap (1).

Install bearings (3) and (4) and race (5) in bearing cap (1). Use replacer to seat race (5) in bearingcap (1). Wide edge of race (5) must face away from face of cap (1).Starting with same thickness of shims (9) as removed, place shims (9) over shaft (8) and ondifferential carrier housing (7). Carefully align holes in shims (9) to holes in carrier housing (7).Place bearing cap (1) over shaft (8) and press bearing cap (1) into position on shaft (8) to differentialcarrier housing (7).Install retaining plate (10) on shaft (8) with three screws (12). Tighten screws (12) 42-54 lb-ft(57-73 N-m) and install new safety wire (11) in screws (12).Install new shims (13) and bearing cover (14) on differential carrier housing (7) with six newlockwashers (15) and screws (16). Select shims (13) of same thickness as removed. Tightenscrews (16) 60.100 lb-ft (81-136 N-m).To measure helical pinion gear (17) bearing preload, wrap twine around helical pinion gear (17) andattach to bearing preload tester. Observe pointer and pull on bearing preload tester until helicalpinion gear (17) starts to rotate. Record value.If original bearings are installed, bearing preload must be 4-8 lb-in. (.5-.9 N-m) If new bearings areinstalled, bearing preload must be 12-18 lb-in. (1.36-2.03 N-m).

NOTEIf preload is not within given limits, perform steps 42through 45.

If preload is within given limits, go to step 47.

Remove six screws (16), lockwashers (15), bearing cover (14), and shims (13) from differentialcarrier housing (7). Remove shims (13) carefully to avoid creasing or damaging shims (13).If preload scale (or torque) reading exceeds limits, add shims (13).

If preload scale (or torque) reading is less than lower limit, remove shims (13).Install shims (13) and bearing cover (14) on differential carrier housing (7) with six lockwashers (15)and screws (16). Carefully align shims (13) with holes in differential carrier housing (7). Tightenscrews (16) 60-100 lb-ft (81-136 N-m).Repeat steps 40 through 45 as necessary.

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47.

48.

49.

50.

51. If contact pattern resembles pattern (14), perform steps 55-59 and 63-69.52. If contact pattern resembles pattern (15), perform steps 55-58, 60, and 63-69.

53. If contact pattern resembles pattern (16), perform steps 55-58, 61, and 63-69.54. If contact pattern resembles pattern (17), perform steps 55-58, 62, and 63-69.

Position shims (2), same thickness pack as removed, on retainer (7) and slide mainshaft (4) intodifferential carrier housing (8). Align inner race (3) with rear roller bearing (9).

Align holes in shims (2), differential carrier housing (8), bore (1), and retainer (7) and install witheight washers (6) and screws (5). Tighten screws (5) 93-120 lb-ft (126-163 N•m).

CAUTION

Correct bevel ring gear and pinion gear contact pattern is criticalto correct operation of differential and differential carrierassembly. Incorrect contact pattern can result in noisy operation orpremature failure of these two gears.

Check bevel ring gear (10) and pinion gear (11) tooth contact pattern by applying blue oil-basepigment to at least three teeth of clean bevel ring gear (10). Turn mainshaft (4) for three fullrotations of bevel ring gear (10).Examine teeth contact pattern (13) of bevel ring gear (10) with pinion gear (11). Pattern should becentered both ways on teeth (12) and cover over two-thirds of tooth (12) contact surface.

NOTEIf pattern is not correct, perform steps 51 through 69.If pattern is correct, go to step 71.

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55.56.

57.

58.

59.

60.

61.62.

63.

64.

65.

66.

67.

68.

69.

70.

Remove six screws (6), lockwashers (7), cover (8), and shims (9) from differential carrier housing (1).Remove safety wire (15), three screws (16), and retaining plate (14). Discard safety wire (15).

Using two jacking screws (17), remove bearing retainer (13) and shim pack (12) from shaft (11)and shaft housing shoulder (10).Remove eight screws (4), washers (5), mainshaft (3), and shim pack (2) from differential carrierhousing (1).

NOTEIf adjustment is needed to correct bevel ring gear and pinion gearcontact pattern, make initial shim changes of at least 0.010 in.(0.25 mm).

For contact pattern of type in step 51, add shims to shim pack (2) and remove shims from shimpack (12).For contact pattern of type in step 52, add shims to shim pack (12) and remove shims from shimpack (2).For contact pattern of type in step 53, remove shims from pack (2) and add shims to shim pack (12).For contact pattern of type in step 54, remove shims from shim pack (12) and add shims to shimpack (2).Using dial indicator, check backlash (20) of bevel ring gear (18) and pinion gear (19).

Backlash (20) should be 0.005-0.015 in. (0.127-0.381 mm).

NOTEIf backlash needs correction, perform steps 55, 56, 57, and 58.If bevel ring gear and pinion gear backlash are within limits, goto step 71.If bevel ring gear and pinion gear backlash are not withinlimits, perform steps 65 and 66.

If backlash (20) is less than limits, add equal amounts of shims to shim packs (2) and (12).

If backlash (20) is greater than limits, remove equal amounts of shims from shim packs (2) and (12).

Carefully place mainshaft (3) and shim pack (2) in differential carrier housing (1) and install witheight washers (5) and screws (4). Tighten screws (4) 93-120 lb-ft (126-163 N•m).Carefully align shim pack (12) to shaft housing shoulder (10) and press on bearing retainer (13)over shaft (11).Install retaining plate (14) on sheet (11) with three screws (16). Tighten screws (16) 42-54 lb-ft (57-73 N•m). Fasten new safety wire (15) to all three screws (16).

Carefully align shims (9) to bearing retainer (13) and install cover (8), shims (9), retainer (13),and shims (12) on shoulder (10) of carrier housing (1) with six new lockwashers (7) and screws (6).Tighten screws (6) 60-100 lb-ft (81-136 N•m).

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TM 9-2320-272-24-4

71.

72.

73.

74.

75.

76.

77.78.

79.

80.

81.

82.

Coat top of new gasket (4) and gasket surface (11) with light coat of sealing compound and positiongasket (4) on differential carrier housing (5).Install access cover (3) on gasket (4) and differential carrier housing (5) with ten washers (2) andscrews (1). Tighten screws (1) 27-40 lb-ft (37-54 N•m).

Coat gasket surface (6) with light coat of sealing compound.

Install new gasket (7) and side cover (8) on differential carrier housing (5) with eight washers (10)and screws (9). Tighten screws (9) 27-40 lb-ft (37-54 N•m).Lubricate sealing surface of new oil seal (13) with GM grease, coat metal contact outer diameterwith sealing compound, and install new gasket (14) and seal (13) in front bearing cover (15) withseal installer tool and arbor press.

NOTEEnsure oil slots on retainer are not blocked with sealing compoundor covered by new gasket.

Coat both sides of new gasket (12) with light coat of sealing compound and position on retainer (18).

Remove eight screws (16) and washers (17) from retainer (18).Install front bearing cover (15), seal (13), gasket (12), and retainer (18) on carrierhousing (5) with eight washers (17) and screws (16). Tighten screws (16) 93-120 lb-ft (126-163 N•m).Lubricate sealing surface of new seal (25) with GAA grease, coat outside metal contact outerdiameter with sealing compound, and install in bearing cover (26).Coat new gasket (24) with light coat of sealing compound and position on differential carrierhousing (5).Place thrust washer (23) over mainshaft (22) and install rear bearing cover (26) with six new lock-washers (28) and screws (27). Tighten screws (27) 24-40 lb-ft (33-54 N•m).

Do not tap or hammer companion flanges on driveshaft assembly.Damage to bearings will result.

Install two companion flanges (21) on mainshaft (22) with two nuts (20). Tighten nuts (20)300-400 lb-ft (407-542 N•m) and install two new cotter pins (19).

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NOTECoat all bearings, races, gears, and thrust washers with clean gearoil before assembly.

83. Install two bearings (1) and (4) on hubs of differential gear housings (2) and (3).

84. Lay one differential gear housing (3), bearing side down, on work surface and install one thrustwasher (8) and side gear (9) in differential gear housing (3).

85. Place four bevel spider gears (6) and thrust washers (7) on spider (10) and place over bevel sidegear (9) in housing (3).

86. Place thrust washer (5) over hub of bevel side gear (11) and position bevel side gear (11) over spidergear assembly in differential gear housing (3).

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TM 9-2320-272-24-4

87.

88.

89.

Carefully align index marks made during disassembly and position two differential gear housings (2)and (3) on helical ring gear (14) and install with eight screws (15) and slotted nuts (13). Tightennuts (13) 130-170 lb-ft (176-231 N•m). Secure with new safety wire (12). Twist ends of safetywire (12) together until wire is tight. Remove and discard excess safety wire (12).Place two races (16) over bearings (1) and (4) on differential gear (17) and set assembly insaddles (18) of differential carrier housing (20). Ensure races (16) seat inside threads of saddles (18).If races (16) do not fully seat in saddles (18), check that helical ring gear (14) is in mesh with helicalpinion gear (19).

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90. Position two caps (3) on saddles (5) and install with four washers (2) and screws (1). Finger-tightenscrews (1).

91. Start two adjusting nuts (6) in threads of saddles (5) and caps (3). Move caps (3) as necessary toalign threads to adjusting nuts (6).

92. Turn adjusting nuts (6) by hand until contact is made with races (4).

93. Ensure helical ring gear (7) aligns with mating helical pinion gear (9). If necessary, loosen andtighten adjusting nuts (6) to align gears.

94. Tighten screws (1) 7-12 lb-ft (9-16 N•m).

NOTEEnsure a notch of each adjusting nut aligns with top center of cap.

95. To establish helical bearing preload, perform step a. or b.

a. Alternately tighten adjusting nuts (6) a total 1.5 to 2.75 notch widths.

b. Tighten each adjusting nut (6) 15-35 lb-in. (1.7-4.0 N•m).96. Install dial indicator on differential carrier housing (8) with indicator plunger perpendicular to edge

of helical ring gear (7).97. Turn helical ring gear (7) one revolution in each direction. Runout reading on dial indicator must

not exceed 0.008 in. (0.20 mm). If runout exceeds this value, loosen adjusting nuts (6) and screws (1)and repeat steps 90 through 95.

98. Reposition dial indicator so plunger contacts tooth (10) and detects motion in plane of rotation ofhelical ring gear (7) as the gear rotates.

99. Hold helical pinion gear (9) still and rock helical ring gear (7) back and forth. Observe backlashreading on dial indicator.

106. Backlash should be 0.005-0.015 in. (0.127-0.381 mm). If reading is outside of these limits, replacehelical ring gear (7) and helical pinion gear (9).

101. Tighten four screws (1) 290-370 lb-ft (393-502 N•m).102. Install two locks (12) of adjusting nut (6) on caps (3) with screws (13). Tighten screws (13)

66-85 lb-ft (90-115 N•m).103. Install new safety wire (11) through four screws (1) and two screws (13). Twist safety wire (11) ends

together, cut off and discard excess safety wire (11), and bend twisted ends of safety wire (11) outof way.

5-460

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install differential and carrier assembly (para. 4-100).

5-461 (5-462 blank)

5-65. SPECIAL

TM 9-2320-272-24-4

Sect ion VI . SPECIAL PURPOSE BODIES MAINTENANCE

5-66.

5-67.5-68.5-69.5-70.5-71.5-72.

5-73.5-74.

5-75.5-76.

5-77.5-78.5-79.5-80.

5-81.

5-82.

5-83.5-84.5-85.5-86.5-87.5-88.

5-89.5-90.

5-91.5-92.

5-93.5-94.

5-95.5-96.

5-97.5-98.5-99.5-100.

Van Body Replacement

Retraceable Beam ReplacementRetractable Beam Drive Shaft and Lock MaintenanceRetractable Beam Rollers ReplacementSide Doors MaintenanceUnderframe Parts ReplacementHinged Floor Maintenance

Exterior Side Panel MaintenanceRear Wall Interior Panels Replacement

Interior Side Panels and Latches ReplacementCeiling and Frame Maintenance

Hinged Roof MaintenanceFront Wall Registers ReplacementCeiling Filler and Side Panels ReplacementCeiling Rear Cover Replacement

Ceiling Air Ducts Replacement

Ceiling Transition Maintenance

Ceiling Deflector and Registers ReplacementRear Splice Plate ReplacementBonnet Frame Parts ReplacementBonnet Access Door MaintenanceBonnet Door Maintenance

Air Conditioner Replacement

Main Wiring Harness ReplacementVan Air Conditioner Wiring Harness ReplacementVan Heater Wiring Harness ReplacementElectric Heater (10 kW) Wiring Harness Replacement

Blackout Bypass Wiring Harness MaintenanceEmergency Lamp Wiring Harness Replacement

Blackout and Clearance Lights Wiring Harness Replacement400 hz Supply Wiring Harness Replacement

Branched 400 hz Receptacle Wiring Harness ReplacementRight and Left Side Blackout Harness MaintenanceTelephone Post Wiring Harness Replacement3 Phase Receptacle Wiring Harness Replacement

5-464

5-468

5-4705-4745-4785-4845-486

5-4905-498

5-5005-5085-5185-5315-5325-5345-536

5-538

5-5425-5435-5445-5495-5545-563

5-5685-570

5-5725-5785-5805-582

5-5885-590

5-5965-5985-6025-604

5-463

5-66. VAN

TM 9-2320-272-24-4

THIS TASK COVERS:

a. Removal b. Installation

APPLICABLE MODELSM934/A1/A2


MATERIALS/PARTSTen locknuts (Appendix D, Item 291)Twelve locknuts (Appendix D, Item 321)

PERSONNEL REQUIREDTwo


EQUIPMENT CONDlTlONl Parking brake set (TM 9-2320-272-10).l Ladders removed (TM 9-2320-272-10).

GENERAL SAFETY INSTRUCTIONSAll personnel must stand clear during liftingoperations.

1. Remove four locknuts (18), screws (13), washers (14), springs (15), and springs (16) from vanbody (1) and two frame brackets (8). Discard locknuts (18).

2. Remove eight locknuts (12) and screws (9) from van body (1) and four frame brackets (8). Discardlocknuts (12).

3. Attach chain to four lifting brackets (2) and lifting device.

WARNING

All personnel must stand clear during lifting operations. Asnapped cable, or swinging or shifting load, may result in injury topersonnel.

NOTESecond assistant will help with steps 4 and 5.

4. Raise van body (1) clear of frame (7), release parking brake, and remove vehicle from under vanbody (1).

5. Lower van body (1) onto jack stands positioned evenly under van body (1).

6. Remove four blocks (5) from frame brackets (8).

NOTESills and hardware will be in position for removal after van bodyhas been removed.

7. Remove ten locknuts (3), bevel washers (4), screws (10, washers (11), and two sills (6) and (17) fromvan body (1). Discard locknuts (3).

8. Remove chain from lifting device and four lifting brackets (2).

5-464

TM 9-2320-272-24-4

5-465

5-66. VAN

TM 9-2320-272-24-4

1.

2.3.

Install two sills (6) and (17) on van body (1) with ten washers (11), screws (10), bevelwashers (4), and new locknuts (3).Position four blocks (5) on frame brackets (8).Attach chain to four lifting brackets (2) and lifting device.

WARNING

All personnel must stand clear during lifting operations. Asnapped cable, or swinging or shifting load, may result in injury topersonnel.

NOTE

4.5.6.7.

8.

Second assistant will help with steps 4 and 5.Raise van body (1) from jack stands, and remove jack stands from under van body (1).Position vehicle under van body (1) and set parking brake.

Lower van body (1) onto frame (7) and align holes of frame brackets (8) and van body (1).Install van body (1) on four frame brackets (8) with eight screws (9) and new locknuts (12).

Install van body (1) on two frame brackets (8) with four springs (15), springs (16), washers (14),screws (13), and new locknuts (18).

9. Remove chains from lifting device and four lifting brackets (2).

5-466

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install ladders (TM 9-2320-272-10).

5-467

TM 9-2320-272-24-4




MATERIALS/PARTSTwo locknuts (Appendix D, Item 274)Seal (Appendix D, Item 614)Seal (Appendix D, Item 615)Seal (Appendix D, Item 616)

REFERENCES (TM)TM 9-237TM 9-2320-272-10TM 9-2320-272-24P

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Van body sides fully expanded and secured(TM 9-2320-272- 10).Retractable beam rollers removed (para. 5-69).Retractable beam drive shaft and lock removed(para. 5-68).

SPECIAL ENVIRONMENTAL CONDlTlONSVehicle must be on level surface.

NOTEAll ten retractable beams are replaced the same way. Thisprocedure is for the left-rear retractable beam.

1. Break welds between side panel (1) and side panel support (13) and remove retractable beam (12)(TM 9-237).

CAUTION

Remove retractable beam slowly from underframe. Failure to do somay result in damage to equipment.

2. Slide retractable beam (12) under side panel (1) and remove from underframe (4) and channel (5).

3. Remove two locknuts (7), washers (8), screws (11), seven screws (10), retainer (9), and seals (2), (3),and (6) from underframe (4). Discard locknuts (7) and seals (2), (3), and (6).

1. Install new seals (6), (3), and (2), and retainer (9) on underframe (4) with seven screws (10), twoscrews (11), washers (8), and new locknuts (7).

CAUTION

Install retractable beam slowly into underframe. Failure to do somay result in damage to equipment .

2. Slide retractable beam (12) under side panel (1) and install in under-frame (4) at channel (5).

3. Install retractable beam (12) by welding retractable beam (12) to side panel (1) and side panelsupport (13) (TM 9-237).

5-468

5-67. RETRACTABLE

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install retractable beam drive shaft and lock (para. 5-68).Install retractable beam rollers (para. 5-69).Retract van body sides (TM 9-2320-272-10).

5-469

TM 9-2320-272-24-4

THIS TASK COVERS:

a. Removalb. Cleaning, Inspection, and Repair

c. Installation



MATERIALS/PARTSFive keys (Appendix D, Item 266)Locknut (Appendix D, Item 297)GAA grease (Appendix C, Item 28)


EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).

SPECIAL ENVIRONMENTAL CONDITIONSVehicle must be on level surface.

PERSONNEL REQUIREDTwo

NOTELeft and right retractable beam drive shafts and locks arereplaced the same. This procedure is for the left retractable beamdrive shaft and lock.

1. Remove locknut (1) and lock (2) from under-frame stud (8). Discard locknut (1).2. Remove screw (4), paw1 (3), and lock (2) from underframe (5).

3. Remove thirty screws (7) and five covers (6) from underframe (5).

4. Remove four setscrews (15) from bushings (14).

CAUTION

Do not bend or strain ratchet shaft during removal. Doing so mayresult in damage to equipment.

NOTERemove all nicks, burrs, and corrosion from ratchet shaft andlubricate before removal.

Direct assistant to catch ratchet shaft components under vanbody during removal.

5. Slowly pull ratchet shaft (9) and remove four bushings (14), nine bushings (13), spacers (12),sprockets (11), and five spacers (10) from under-frame (5).

5-470

5-68. RETRACTABLE

TM 9-2320-272-24-4

5-471

TM 9-2320-272-24-4

1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Remove five keys (11) and bushings (10) from sprockets (4). Discard keys (11).4. Inspect bushings (10), (6), and (8) for wear and damage. If worn or damaged replace bushings (10), (6),

or (8).5. Inspect ratchet shaft (2) for burrs, nicks, and corrosion. If damaged, repair with file or emery cloth.

If damage is excessive, replace.

6. Test spring action of lock plunger (14). If spring action is weak, replace lock (14).7. Install five new keys (11) and bushings (10) on sprockets (4).

Do not bend or strain ratchet shaft during installation. Doing somay result in damage to equipment.

NOTEBevel forward end of ratchet shaft for installation.

Apply GAA grease on two feet of forward end of ratchet shaft forinstallation.Direct assistant to install ratchet shaft components under vanbody when installing ratchet shaft.

1. Slowly insert ratchet shaft (2) into underframe (1) and install five spacers (3), sprockets (4), spacers (5),nine bushings (6), and four bushings (8).

2. Install four setscrews (9) in bushings (8) in underframe channels (7).

3. Lubricate ratchet shaft (2) with GAA grease (LO 9-2320-272-12).

4. Install five covers (17) on underframe (1) with thirty screws (18).5. Install lock (14) and paw1 (15) on underframe stud (12) and underframe (1) with new

locknut (13) and screw (16).

5-472

5-68. RETRACTABLE

TM 9-2320-272-24-4

5-473

TM 9-2320-272-24-4

THIS TASK COVERS:a. Support Roller Removal c. End Roller Removalb. Support Roller Installation d. End Roller Installation

APPLICABLE MODELS REFERENCES (TM)M934/A1/A2 TM 9-2320-272-10

TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITION

MATERIALS/PARTSFour cotter pins (Appendix D, Item 72)

Parking brake (TM 9-2320-272-10).Van body sides fully expanded and secured(TM 9-2320-272-10).

NOTE

All support rollers are removed basically the same way, Thisprocedure is for left-rear support rollers.

1. Remove seven screws (2), clamps (3), and cover (4) from underframe (1)2. Remove two cotter pins (5), support roller shaft (7), and support roller (6) from underframe (1).

Discard cotter pins (5).

1. Install support roller (6) on underframe (1) with support roller shaft (7) and two new cotter pins (5).2. Install cover (4) on underframe (1) with seven clamps (3) and screws (2).

5-474

TM 9-2320-272-24-4

5-475

TM 9-2320-272-24-4

NOTEAll end rollers are replaced basically the same way. Thisprocedure is for left-rear end rollers.

1. Remove support roller (task a.).2. Remove two cotter pins (2), end roller shaft (3), and end roller (4) from underframe (1). Discard

cotter pins (2).

1. Install end roller (4) on underframe (1) with end roller shaft (3) and two new cotter pins (2).2. Install support roller (task b.).

5-476

TM 9-2320-272-24-4

FOLLOW-ON TASK: Retract van body sides (TM 9-2320-272-10).

5-477

TM 9-2320-272-24-4




TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Rivet gun

MATERIALS/PARTSTwo cotter pins (Appendix D, Item 51)Two lockwashers (Appendix D, Item 364)Three rivets (Appendix D, Item 548)Sixteen rivets (Appendix D, Item 547)Gasket (Appendix D, Item 229)Seal (Appendix D, Item 605)Seal (Appendix D, Item 633)Adhesive sealant (Appendix C, Item 7)Sealing compound (Appendix C, Item 67)

REFERENCES (TM)TM 43-0213TM 9-2320-272-10TM 9-2320-272-24P

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Van body sides fully expanded and secured(TM 9-2320-272-10).Side door window removed (para. 3-350).

NOTELeft and right side doors are replaced the same way. Thisprocedure is for the left side door.

1. Remove two screws (1), lockwashers (2), bracket (3), and door check lever (4) from door (5). Discardlockwashers (2).


2. Remove fifteen screws (6) and door (5) from side panel of van body (7).

5-478

5-70. SIDE

TM 9-2320-272-24-4

5-479

TM 9-2320-272-24-4

1. Remove three rivets (13), handle (12), and gasket (11) from pocket (10). Discard rivets (13) andgasket (11).

2. Remove sixteen rivets (14) and pocket (10) from outer panel (9). Discard rivets (14).3. Remove two cotter pins (23), screws (19), washers (20), and rods (21) from upper case (2), lower

case (18), and center case (22). Discard cotter pins (23).

4. Remove pin (26) and handle (25) from center case (22).

5. Remove four screws (27) and center case (22) from inner panel (24).

6. Remove eight screws (1), upper case (2), and lower case (18) from inner panel (24).

7. Remove fourteen screws (8), molding (7), seal (6), hinge (5), and seal (4) from door frame (17).Discard seals (4) and (6).

8. Break adhesive seal and remove two moldings (3) from inner panel (24).9. Remove two screws (16) and moldings (15) from inner panel (24).



3. Inspect all movable components of center case (22) and lower and upper cases (2) and (18) for properoperation. Replace center case (22), lower case (18), or upper case (2) if damaged or defective.

4. Inspect rods (21) for breaks and bends. Replace rods (21) if broken or bent.5. Inspect moldings (3) and (15) and pocket (10) for cracks and bends. Replace moldings (3), (15), or

pocket (10) if cracked or bent.

6. Inspect outer panel (9), door frame (17), and inner panel (24) for damage. Replace entire side door ifeither is damaged.

NOTEApply rustproofing compound to all inside surfaces and boxed-inareas (TM 43-0213).

Apply sealing compound to all exterior joints for installation.

1. Install two moldings (15) on inner panel (24) with two screws (16).

2. Apply adhesive to two moldings (3) and install on inner panel (24).

3. Install new seal (4), hinge (5), new seal (6), and molding (7) on door frame (17) with fourteenscrews (18).

4. Install upper case (2) and lower case (18) on inner panel (24) with eight screws (1).5. Install center case (22) on inner panel (24) with four screws (27).6. Install handle (25) on center case (22) with pin (26).

7. Install two rods (21) on center (22), upper case (2), and lower case (18) with two new cotter pins (23),washers (20), and screws (19).

8. Install pocket (10) on outer panel (9) with sixteen new rivets (14).

9. Install new gasket (11) and handle (12) on pocket (10) with three new rivets (13).

5-480

5-70.. SIDE

TM 9-2320-272-24-4

5-481

TM 9-2320-272-24-4


1. Install door (5) on side panel of van body (7) with fifteen screws (6).2. Install door check lever (4) and bracket (3) on door (5) with two new lockwashers (2) and screws (1).

5-482

5-70. SIDE

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install side door window (para. 3-350).Retract van body sides (TM 9-2320-272-10).

5-483

5-71. UNDERFRAME

TM 9-2320-272-24-4

THIS TASK COVERS:



TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONRivet gun Parking brake set (TM 9-2320-272-10).

MATERIALS/PARTS SPECIAL ENVIRONMENTAL CONDITIONSEight lockwashers (Appendix D, Item 400) Vehicle must be on level surface.Two seals, 206 in. (Appendix D, Item 617)Thirty-two rivets (Appendix D, Item 558)Sealing compound (Appendix C, Item 67)


1. Remove one hundred thirty-eight screws (14), two retainers (15), channels (12), and seals (13) fromunderframe (1). Discard seals (13).

2. Remove thirty-two screws (4) and four covers (5) from under-frame (1).3. Remove eight nuts (3), lockwashers (2), screws (7), and four plates (6) from under-frame (1). Discard

lockwashers (2).

4. Remove thirty-two rivets (8) and eight tiedowns (9) from underframe (1). Discard rivets (8).

5. Remove four screws (11) and angle bracket (10) from underframe (1).

1. Install angle bracket (10) on underframe (1) with four screws (11).

2. Install eight tiedowns (9) on underframe (1) with thirty-two new rivets (8).3. Install four plates (6) on underframe (1) with eight screws (7), new lockwashers (2), and nuts (3).

4. Install four covers (5) on underframe (1) with thirty-two screws (4).

NOTEApply sealing compound to exterior joints for installation.

5. Install two new seals (13), channels (12), and retainers (15) on underframe (1) with one hundredthirty-eight screws (14).

5-484

5-71. UNDERFRAME

TM 9-2320-272-24-4

5-485

5-72. HINGED

TM 9-2320-272-24-4



APPLICABLE MODELS REFERENCES (TM)M934/A1/A2 TM 9-237

TOOLSTM 9-2320-272-10TM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1)Rivet gun EQUIPMENT CONDITION

MATERIALS/PARTSHinged end panel open (TM 9-2320-272-10)Van body sides extended (TM 9-2320-272-10).

Fifty-six rivets (Appendix D Item 549) Counterbalance removed (para. 3-356).Four seals, 39 in. (Appendix D, Item 617)Seal, 203 in. (Appendix D, Item 631) SPECIAL ENVIRONMENTAL CONDITIONSAdhesive (Appendix C, Item 3) Vehicle must be on level surface.Sealing compound (Appendix C, Item 67)

NOTELeft and right hinged floors are maintained the same way. Thisprocedure is for left hinged floor.

NOTEAssistant will help with step.

Remove fifty-five screws (3), four screws (2), and hinged floor (1) from hinge (4).

5-486

TM 9-2320-272-24-4

1. Remove four screws (5) and two pivots (6) from hinged floor (1).2. Remove thirty screws (7), two retainers (8), four seals (9), and two channels (15) from hinged

floor (1). Discard seals (9).3. Remove ten screws (13) and five pads (14) from hinged floor (1).

4. Remove four screws (11) and handle (12) from hinged floor (1).

5. Remove seal (10) from hinged floor (1). Discard seal (10).

NOTEPerform step 6 only if inspection requires replacement of hinge.

6. Remove fifty-six rivets (16) and hinge (4) from under-frame (17). Discard rivets (16).

5-487

5-72. HINGED

TM 9-2320-272-24-4

1. For general cleaning instructions, refer to para. 2-14.2. For general inspection instructions, refer to para. 2-15.3. Inspect hinged floor (1) for cracked, broken, and tom floor plates. If cracked, broken, or torn, replace

hinged floor (1) (TM 9-237).4. Inspect retainers (8) and channels (15) for bends and breaks. If bent or broken, replace retainers (8) or

channels (15).5. Inspect hinge (4) for breaks, cracks, and smooth operation. If cracked, broken, or not operating

properly, replace hinge (4).

NOTEApply sealing compound to exterior joints prior to installation.Insulate exterior joints and areas of metal-to metal contact withadhesive.

Perform step 1 only if hinge is to be replaced .1. Install hinge (4) on under-frame (17) with fifty-six new rivets (16).

2. Install new seal (10) on hinged floor (1).3. Install handle (12) on hinged floor (1) with four screws (11).4. Install five pads (14) on hinged floor (1) with ten screws (13).5. Install two channels (15), four new seals (9), and two retainers (8) on hinged floor (1) with thirty

screws (7).6. Install two pivots (6) on hinged floor (1) with four screws (5).


Install hinged floor (1) on hinge (4) with fifty-five screws (3) and four screws (2).

5-488

5-72. HINGED

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install counterbalance (para. 3-356).Close hinged end panel (TM 9-2320-272-10).Retract van body sides (TM 9-2320-272-10).

5-489

5-73. EXTERIOR

TM 9-2320-272-24-4

THIS TASK COVERS:a. Disassemblyb. Cleaning and inspection

c. Assembly


TM 9-2320-272-24PTOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Rivet gun

MATERIALS/PARTSTwo hundred forty-eight rivets (Appendix D,

Item 547)Twenty-four rivets (Appendix D, Item 551)One hundred eighty-nine rivets (Appendix D,

Item 550)Two seals, 86 in. (Appendix D, Item 617)Two seals, 206 in. (Appendix D, item 617)Two seals, 6 in. (Appendix D, Item 617)Seal, 242 in. (Appendix D, Item 617)Seal, 204 in. (Appendix D, Item 618)Channel seal (Appendix D, Item 36)Adhesive (Appendix C, Item 7)Sealing compound (Appendix C, Item 67)

EQUIPMENT CONDlTlONParking brake set (TM 9-2320-272-10).Van body fully expanded and secured(TM 9-2320-272-10).Side panel front lock removed (para. 3-369).Side panel rear lock removed (para. 3-368).Side door removed (para. 5-70).Retractable window removed (para. 3-351).

SPECIAL ENVIRONMENTAL CONDITIONSVehicle must be on level surface.

NOTELeft and right exterior side panels are disassembled the same.This procedure covers the right exterior side panel.

1. Remove twenty-five screws (5) and retainers (3) and (15) from side panel frame (14).2. Remove seals (2) and (4) and channel (1) from side panel frame (14). Discard seals (2) and (4).

3. Remove thirty screws (12) and five retainers (13) from seal (10) at side panel frame (14).4. Remove sixty-two screws (11), six retainers (9), and seal (10) from side panel frame (14). Discard

seal (10).

5. Remove six screws (8), two retainers (7), and seals (6) from side panel frame (14). Discard seals (6).

5-490

TM 9-2320-272-24-4

5-491

5-73. EXTERIOR

TM 9-2320-272-24-4

6.

7.

8.

9.

10.

11.12.

Remove one hundred eighty-nine rivets (19), bracket (17), and seal (18) from skins (2) and (11) andside panel frame (8). Discard rivets (19) and seal (18).Remove eighty-two nuts (5), screws (1), four screws (10), two retainers (4), and seals (3) from sidepanel frame (8). Discard seals (3).Remove channel seal (9) from doorway of side panel frame (8). Discard channel seal (9).

Remove nine screws (6) and molding (7) from doorway of side panel frame (8).NOTE

Perform steps 10 through 12 if skin is to be replaced.Assistant will help with steps 10 through 12.

Remove two hundred forty-eight rivets (12) and skins (2) and (11) from side panel frame (8). Discardrivets (12).Remove eight screws (15) and two ladder hangers (14) from side panel frame (8).Remove twenty-four rivets (16) and lower skin (13) from side panel frame (8). Discard rivets (16).

5-492

TM 9-2320-272-24-4

5-73. EXTERIOR SIDE PANEL MAINTENANCE (Contd)

5-493

TM 9-2320-272-24-4




3. Inspect five retainers (12), retainers (13), (5), and (6) for cracks and bends. If cracked or broken,replace.

4. Inspect bracket (3), retainers (9) and (10), and channel (11) for rust corrosion and breaks. If rustedcorroded, or broken, replace.

5. Inspect molding (4), two ladder hangers (8), and side panel frame (2) for cracks, breaks, andwarpage. If cracked, broken, or warped, replace.

6. Inspect skins (1) and (14) and lower skin (7) for tears and punctures. If torn or punctured, replace.

NOTEl Perform steps 1 through 3 if skin was removed.l Assistant will help with steps 1 through 3.

1. Install lower skin (7) on side panel frame (2) with twenty-four new rivets (23).

2. Install two ladder hangers (8) on side panel frame (2) with eight screws (22).3. Install skins (1) and (14) on side panel frame (2) with two hundred forty-eight new rivets (21).

NOTEl Apply sealing compound to exterior joints for installation.l Apply adhesive to rubber and metal surfaces for installation.

4. Install molding (4) on doorway of side panel frame (2) with nine screws (18).5. Install new channel seal (19) on doorway of side panel frame (2).6. Install two new seals (16) and retainers (5) on side panel frame (2) with eighty-two screws (15),

nuts (17), and four screws (20).

7. Install new seal (25) and bracket (24) on skins (1) and (14) and side panel frame (2) with onehundred eighty-nine new rivets (26).

5-494

5-73. EXTERIOR

TM 9-2320-272-24-4

5-495

TM 9-2320-272-24-4


8. Install two new seals (6) and retainers (7) on side panel frame (14) with six screws (8).9. Install new seal (10) and six retainers (9) on side panel frame (14) with sixty-two screws (11).

10. Install five retainers (13) on side panel frame (14) and seal (10) with thirty screws (12).NOTE

New seals may need to be formed to fit on side panel frame.

11. Install channel (1), new seals (2) and (4), retainer (3), and retainer (15) on side panel frame (14)with twenty-five screws (5).

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TM 9-2320-272-24-4


FOLLOW-ON TASKS: l Install side panel rear lock (para. 3-368).l Install side panel front lock (para. 3-369).l Install retractable window (para. 3-351).l Install side door (para. 5-70).l Retract van body sides (TM 9-2320-272-10).

5-497

TM 9-2320-272-24-4

5-74. REAR WALL INTERIOR PANELS REPLACEMENT


INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDlTlONM934/A1/A2 l

lTOOLS ll

General mechanic’s tool kit (Appendix E, Item 1)l

MATERIALS/PARTS ll

Sealing compound (Appendix C, Item 67) l.

REFERENCES (TM) ll

TM 9-2320-272-10 l

TM 9-2320-272-24P l

Parking brake set (TM 9-2320-272-10).Rear doors opened (TM 9-2320-272-10).Van body sides fully expanded and secured(TM 9-2320-272-10).Inside telephone jack post removed (para. 3-374).Blackout light switch removed (para. 3-373).Fire extinguisher bracket removed (para. 3-416).Electrical load center removed (para. 4-161).Electrical junction box removed (para. 4-163).Converter outlet box removed (para. 4-169).Heater thermostat removed (para. 4-165).

SPECIAL ENVIRONMENTAL CONDlTlONSVehicle must be on a level surface.

NOTEl Rear wall exterior panels are not serviceable and if damaged

are replaced as a unit with rear wall assembly.

l Left and right rear wall interior panels are replaced the sameway. This procedure is for the left rear wall interior panel.


1. Remove thirteen screws (4) and molding (1) from panel (2) and header (3).

2. Remove twenty-two screws (5) and panel (2) from header (3).3. Remove eight screws (9) and two gussets (8) from skin (7) and underframe (6).

NOTEl Apply sealing compound to exterior joints prior to installation.

l Assistant will help with step 2.

1. Install two gussets (8) on skin (7) and underframe (6) with eight screws (9).2. Install panel (2) on header (3) with twenty-two screws (5).3. Install molding (1) on panel (2) and header (3) with thirteen screws (4).

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TM 9-2320-272-24-4

5-74. REAR WALL INTERIOR PANELS REPLACEMENT (Contd)

FOLLOW-ON TASKS: l Install heater thermostat (para. 4-165).l Install converter outlet box (para. 4-169).l Install electrical junction box (para. 4-163).l Install electrical load center (para. 4-161).l Install fire extinguisher bracket (para. 3-416).l Install blackout light switch (para. 3-373).l Install inside telephone jack post (para. 3-374).l Retract van body sides (TM 9-2320-272-10).l Close rear doors (TM 9-2320-272-10).

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TM 9-2320-272-24-4

5-75. INTERIOR SIDE PANELS AND LATCHES REPLACEMENT

THIS TASK COVERS:


INITIAL SETUP:


TOOLS



MATERIALS/PARTSl Parking brake set (TM 9-2320-272-10).l Van body sides fully expanded and secured

Two cotter pins (Appendix D, Item 51)Gasket (Appendix D, Item 231)Three grommets (Appendix D, Item 251)Six lockwashers (Appendix D, Item 364)O-ring (Appendix D, Item 479)Four rubber bumpers (Appendix D, Item 563)Primer (Appendix C, Item 57)Sealing compound (Appendix C, Item 67)Adhesive (Appendix C, Item 7)

(TM 9-2320-272-10).l Hinged end panels removed (para. 4-155).l Hinged floor removed (para. 5-72).l Hinged roof removed (para. 5-77).l Side doors removed (para. 5-70).

SPECIAL ENVIRONMENTAL CONDITIONSVehicle must be on a level surface.

NOTELeft and right interior side panels are replaced the same way. Thisprocedure is for right interior side panel.

1. Remove six screws (1) and three hooks (2) from side panel frame (3).

2. Remove six screws (5) and three clips (6) from side panel frame (3).

3. Remove two screws (8) and striker (7) from side panel frame (3).

4. Remove two nuts (4), screws (10), lockwashers (11), and door check assembly (9) from doorangle (15). Discard lockwashers (11).

5. Remove two screws (12), striker (13), and two spacer plates (14) from side panel frame (3).

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5-75. INTERIOR SIDE PANELS AND LATCHES REPLACEMENT (Contd)

5-501

TM 9-2320-272-24-4


6. Remove two screws (2) and grommets (3) from side panel frame (1). Discard grommets (3).7. Remove four screws (11) and two clips (12) from panel (13) and side panel frame (1).8. Remove four screws (16), washers (17), and rubber bumpers (18) from panel (5). Discard rubber

bumpers (18).9. Remove eight screws (15) and four wood spacers (19) from panel (5).

10. Remove eight screws (21) and four hangers (20) from panel (5).

11. Remove four screws (23) and junction box (24) from panel (5).

12. Remove eight screws (7) and plate (8) from panel (5).

13. Remove eleven screws (22) and molding (25) from panel (5).NOTE

Assistants will help with steps 14 and 15.14. Remove thirty-three screws (10) and panel (13) from side panel frame (1).

15. Remove fifty-eight screws (9), molding (14), and panel (5) from side panel frame (1).

16. Remove moldings (26), (4), and (6) from panel (5).

17. Remove two moldings (27), moldings (28), and moldings (29) from panel (5).

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TM 9-2320-272-24-4


5-503

TM 9-2320-272-24-4


18. Remove eight screws (15) and plate (14) from panel (16).

NOTE

19.

20.

21.

22.

23.

24.25.

26.27.

Assistant will help with step 19.Remove thirty-three screws (13), moldings (27), (28), (29), (12), (17), and (18), and panel (16) fromside panel frame (4).Remove nut (25) and washer (24) from latch (23).

Remove two screws (7), plate (8), gasket (9), shank (5), and O-ring (6) from latch (23). DiscardO-ring (6) and gasket (9).Remove two cotter pins (22), pins (20), clevis (26), and clevis (21) from latch (23). Discard cotter pins (22).Remove four nuts (11), lockwashers (10), and latch (23) from side panel frame (4). Discardlockwashers (10).Remove two screws (31) and retainer (30) from side panel frame (4).Remove clevis (21) from flush bolt (3).

Remove clevis (26) from horizontal bar (19).Remove horizontal bar (19) and flush bolt (3) from side panel frame (4).

NOTERepeat steps 18 through 27 for removal of each front latchassembly.

28. Remove screw (1) and grommet (2) from side panel frame (4). Discard grommet (2).

NOTEl Insulate areas of dissimilar metal-to-metal contact with zinc

chromate primer.l Apply sealing compound to exterior joints prior to installation.l Apply adhesive to rubber and metal surfaces.

1. Install new grommet (2) on side panel frame (4) with screw (1).

2. Position horizontal bar (19) and flush bolt (3) in side panel frame (4).3. Install clevis (26) on horizontal bar (19).

4. Install clevis (21) on flush bolt (3).

5. Install retainer (30) on side panel frame (4) with two screws (31).

6. Install latch (23) on side panel frame (4) with four new lockwashers (10) and nuts (11).7. Install clevises (26) and (21) on latch (23) with two pins (20) and new cotter pins (22).8. Install new O-ring (6), shank (5), new gasket (9), and plate (8) on latch (23) with two screws (7).9. Install washer (24) and nut (25) on shank (5) and latch (23).

NOTEl Insulate entire structure with fibrous glass felt insulation.

l Assistant will help with step 10.10. Install panel (16) and moldings (27), (28), (29), (12), (17), and (18) on side panel frame (4) with

thirty-three screws (13).

11. Install plate (14) on panel (16) with eight screws (15).NOTE

Repeat steps 2 through 11 for installation of each front latchassembly.

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5-505

TM 9-2320-272-24-4


12.

13.14.

15.

16.

17.

18.19.20.21.22.

Install moldings (6), (4), and (25) on panel (5).

NOTEl Assistants will help with steps 13 and 14.l Insulate entire structure with fibrous glass felt insulation.

Install panel (5) and molding (14) on side panel frame (1) with fifty-eight screws (9).Install panel (13) on side panel frame (1) with thirty-three screws (10).Install molding (24) on panels (5) and (13) with eleven screws (21).

Install plate (8) on panel (5) with eight screws (7).Install junction box (23) on panel (5) with four screws (22).Install four hangers (20) on panel (5) with eight screws (19).Install four wood spacers (26) on panel (5) with eight screws (15).Install four new rubber bumpers (18) on panel (5) with four washers (17) and screws (16).Install two clips (12) on panel (13) with four screws (11).Install two new grommets (3) on side panel frame (1) with two screws (2).

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TM 9-2320-272-24-4


23. Install two spacer plates (39) and striker (38) on side panel frame (1) with two screws (37).24. Install door check assembly (34) on door angle (40) with two new lockwashers (36), screws (35), and

nuts (30).

25. Install striker (32) on side panel frame (1) with two screws (33).

26. Install three clips (29) on side panel frame (1) with six screws (31).27. Install three hooks (28) on side panel frame (1) with six screws (27).

FOLLOW-ON TASKS: l Install side doors (para. 5-70).l Install hinged roof (para. 5-77).l Install hinged floor (para. 5-72).l Install hinged end panels (para. 4-155).l Retract van body sides (TM 9-2320-272-10).

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TM 9-2320-272-24-4

5-76. CEILING AND FRAME MAINTENANCE

THIS TASK COVERS:a. Removal c. Installationb. Cleaning and Inspection

INITIAL SETUP:



MATERlALS/PARTSSix lockwashers (Appendix D, Item 392)One-hundred sixteen rivets (Appendix D,

Item 552)One-hundred forty-four rivets (Appendix D,

Item 553)Eighty-eight rivets (Appendix D, Item 551)Two-hundred eight rivets (Appendix D,

Item 542)Seal (Appendix D, Item 619)Seal (Appendix D, Item 620)Adhesive (Appendix C, Item 3)Primer (Appendix C, Item 57)

TM 9-2320-272-24P

EQUIPMENT CONDITIONl Parking brake set (TM 9-2320-272-10).l Van body sides fully expanded and secured

(TM 9-2320-272-10).l Ceiling air ducts removed (para. 5-81).l Ceiling filler and side panels removed (para. 5-79).l Ceiling rear cover removed (para. 5-80).l Rear doors removed (para. 4-154).l Ceiling transition removed (para. 5-82).


1. Remove one-hundred two rivets (6), ceiling panel (5), and two liner strips (1) from roof frame (2).Discard rivets (6).

2. Remove ninety-three rivets (4), ceiling panel (3), and two liner strips (1) from roof frame (2). Discardrivets (4).

5-508

TM 9-2320-272-24-4

5-76. CEILING AND FRAME MAINTENANCE (Contd)

5-509

TM 9-2320-272-24-4


3. Remove ninety-two rivets (3), ceiling panel (4), and two liner strips (2) from roof frame (1). Discardrivets (3).

4. Remove seventy-six rivets (5), ceiling panel (6), and three liner strips (2) from roof frame (1).Discard rivets (5).

NOTELeft and right side moldings are removed the same way. Thisprocedure covers the right side.

5. Remove fifty-nine screws (11), molding (10), molding (12), and seal (9) from roof frame (1). Discardseal (9).

6. Remove six nuts (13), screws (7), lockwashers (18), and two lifting brackets (17) from roof frame (1).Discard lockwashers (18).

NOTEl Perform steps 7 and 8 only if roof is damaged and is to be

removed (task b).

l Assistant will help with steps 7 and 8.7. Remove one-hundred twenty-six rivets (15), eighteen rivets (14), and one-hundred sixteen rivets (8)

connecting roof panel (16) to roof frame (1). Discard rivets (8), (14), and (15).8. Remove roof panel (16) from roof frame (1) by lifting roof panel (16) and placing on supports.

5-510

TM 9-2320-272-24-4


5-511

TM 9-2320-272-24-4


9. Remove twenty-three screws (2) and moldings (1), (3), and (4) from van body (11).10. Remove three screws (6) and angle bracket (7) from retainer (8)11. Remove fifteen screws (5), seal (9), retainer (8), and woodblock (10) from van body (11). Discard

seal (9).


1. For general cleaning instructions, refer to para. 2-14.2. Inspect moldings (1), (3), and (4) for bends and breaks. If bent or broken, replace molding (l),

(3), or (4).3. Inspect angle bracket (7) and retainer (8) for cracks and breaks. If cracked or broken, replace.4. Inspect woodblock (10) for breaks. If broken, replace woodblock (10).5. Inspect moldings (13) and (14) for bends, breaks, and warpage. If bent, broken, or warped, replace

molding (13) or (14).

6. Inspect lifting bracket (12) for breaks and cracks. If broken or cracked, replace lifting bracket (12).7. Inspect roof panel (16) for tears and punctures. If torn or punctured, replace roof panel (16).8. Inspect roof frame (15) for breaks, warpage, and broken bows. If roof frame (15) is damaged, replace

entire roof assembly.9. Inspect ceiling panels (17), (18), (19), and (20) for cracks and punctures. If cracked or punctured,

replace.

5-512

TM 9-2320-272-24-4


5-513

TM 9-2320-272-24-4


l Apply adhesive prior to installation.l Insulate areas of dissimilar metal-to-metal contact with zinc

chromate primer.

1. Install woodblock (10), new seal (9), and retainer (8) on van body (11) with fifteen screws (5). Leavethree center holes of retainer open for angle bracket (7) installation.

2. Install angle bracket (7) on retainer (8) with three screws (6).3. Install moldings (3), (4), and (1) on van body (11) with twenty-three screws (2).

NOTEl Perform steps 4 and 5 only if roof panel was removed.l Insulate entire structure with fibrous glass felt insulation.

l Assistant will help with steps 4 and 5.4. Lift roof panel (22) from supports and position on roof frame (20).5. Install roof panel (22) on roof frame (20) with one-hundred sixteen new rivets (13), eighteen new

rivets (19), and one-hundred twenty-six new rivets (21).6. Install two lifting brackets (23) on roof frame (20) with six new lockwashers (24), screws (12), and

nuts (18).NOTE

Left and right side moldings are installed the same way. Thisprocedure covers the right side.

7. Install new seal (14), molding (15), and molding (17) on roof frame (20) with fifty-nine screws (16).

5-514

TM 9-2320-272-24-4


5-515

TM 9-2320-272-24-4



8. Install ceiling panel (6) and three liner strips (2) on roof frame (1) with seventy-six new rivets (5).9. Install ceiling panel (4) and two liner strips (2) on roof frame (1) with ninety-two new rivets (3).

10. Install ceiling panel (7) and two liner strips (2) on roof frame (1) with ninety-three new rivets (8).

11. Install ceiling panel (9) and two liner strips (2) on roof frame (1) with one-hundred two newrivets (10).

5-516

TM 9-2320-272-24-4


FOLLOW-ON TASKS: l Install rear doors (para. 4-154).l Install ceiling transition (para. 5-82).l Install ceiling rear cover (para. 5-80).l Install ceiling filler and side panels (para. 5-79).l Install ceiling air ducts (para. 5-81).l Retract van body sides (TM 9-2320-272-10).

5-517

TM 9-2320-272-24-4

5-77. HINGED ROOF MAINTENANCE



INITIAL SETUP:


TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUlPMENT CONDITIONLifting device l Parking brake set (TM 9-2320-272-10).Rivet gun l Van body sides fully expanded and securedFour chains (TM 9-2320-272-10).

MATERIALS/PARTSThree cotter pins (Appendix D, Item 56)Fifty-two rivets (Appendix D, Item 555)One-hundred fifty-seven rivets (Appendix D,

Item 553)Seal, 206 in. (Appendix D, Item 633)Seal, 206 in. (Appendix D, Item 618)Seal, 35 in. (Appendix D, Item 621)Seal, 206 in. (Appendix D, Item 622)Seal, 35 in. (Appendix D, Item 606)Two cushion pads (left side) (Appendix D,

Item 90)Two cushion pads (Right side) (Appendix D,

Item 91)Gasket (Appendix D, Item 232)O-ring (Appendix D, Item 464)Twenty-four rivets (Appendix D, Item 554)Four grommets (Appendix D, Item 251)Primer (Appendix C, Item 57)Sealing compound (Appendix C, Item 67)Adhesive (Appendix C, Item 7)

l Hinged roof-operated blackout circuit plungersremoved (para. 3-377).

l Ceiling rear cover removed (para. 5-80).l Ceiling filler and side panels removed (para. 5-79).l Left and right side blackout harness removed

(para. 5-98).



NOTELeft and right hinged roofs are maintained the same way. Thisprocedure covers right side.

1. Attach four chains to lifting device and hinged roof (1). Remove slack from chains.2. Remove four screws (3), two angle brackets (2), and holding rods (4) from hinged roof (1).

5-518

TM 9-2320-272-24-4

5-77. HINGED ROOF MAINTENANCE (Contd)

WARNING

All personnel must stand clear during lifting operations. Aswinging or shifting load may cause injury to personnel.


3. Remove sixty-nine screws (5) from van body (6) and hinged roof (1). Lift hinged roof (1) and positionon supports.

4. Remove chains from lifting device and hinged roof (1).

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TM 9-2320-272-24-4


b. Disassembly

1. Remove twelve screws (27) and three clamps (28) from hinged roof frame (1).2. Remove six screws (25) and three holder assemblies (26) from hinged roof frame (1).

3. Remove thirty screws (5) and moldings (4), (6), and (7) from panels (2) and (18).4. Remove four screws (11) and handle (12) from panel (2).5. Remove ten screws (13) and cover (14) from panel (2).6. Remove six screws (9) and plate (8) from panel (2).

7. Remove six screws (19) and three bars (20) from fillers (22).

8. Remove six screws (21) and three fillers (22) from panels (2) and (8).

9. Remove two screws (16) and molding (15) from panels (2) and (18).10. Remove moldings (3), (23), and (24) from panels (2) and (18).

11.12.


Remove fifty-five screws (10) and panel (2) from hinged roof frame (1).Remove forty-one screws (17) and panel (18) from hinged roof frame (1).

5-520

TM 9-2320-272-24-4


5-521

TM 9-2320-272-24-4


13.14.

15.16.

17.

18.

19.

20.21.

22.23.

24.25.

26.

27.

Remove sixty-eight screws (26), hinge (14), and seal (13) from hinged roof frame (11). Discard seal (13).Remove twenty-four rivets (29), retainer (30), and seal (28) from hinged roof frame (11). Discardseal (28) and rivets (29).Remove cushion pads (12) and (27) from hinged roof frame (11). Discard cushion pads (12) and (27).Remove fifty-two rivets (32), retainer (34), and seal (35) from hinged roof frame (11). Discardrivets (32) and seal (35).Remove seals (31) and (33) from hinged roof frame (11). Discard seals (31) and (33).

Remove padlock and chain (2) and chain hook (1) from angle bracket (37).

Remove three screws (38) and angle bracket (37) from skin (7).Remove cotter pin (24), nut (23), and washer (22) from handle (3). Discard cotter pin (24).Remove two screws (4), handle (3), plate (5), gasket (6), and O-ring (36) from skin (7). DiscardO-ring (36) and gasket (6).Remove two cotter pins (19), pins (16), and clevises (18) from latch (17). Discard cotter pins (19).Remove four nuts (21), washers (20), and latch (17) from hinged roof frame (11).

Remove clevises (18) from bars (15) and (25).Remove bars (15) and (25) from hinged roof frame (11).

Remove four screws (9) and grommets (10) from hinged roof frame (11). Discard grommets (10).

NOTEl Perform step 27 only if skin is to be removed (task c).l Assistant will help with step 27.

Remove one-hundred fifty-seven rivets (8) and skin (7) from hinged roof frame (11). Discardrivets (8).

5-522

TM 9-2320-272-24-4


5-523

TM 9-2320-272-24-4


1.

2.

3.

4.

5.

6.7.

8.

9.

10.11.12.

For general cleaning instructions, refer to para. 2-14.Inspect panels (2) and (11) for cracks and breaks. Replace panels (2) and (11) if cracked or broken.

Inspect moldings (3), (4), (5), (6), (10), (14), and (15) for warpage and breaks. Replace moldings (3),(4), (5), (6), (10), (14), and (15) if moldings are warped or broken.Inspect plate (7), handle (8), cover (9), three bars (12), and fillers (13) for bends and breaks. Replaceplate (7), handle (8), cover (9), bars (12), and fillers (13) if bent or broken.Inspect three clamps (17) and holder assemblies (16) for breaks and proper operation. Replaceclamps (17) and holder assemblies (16) if damaged.Inspect hinge (23) for breaks and proper operation. Replace hinge (23) if damaged.Inspect retainers (28) and (29) for cracks and breaks. Replace retainer (28) or (29) if cracked or broken.

Inspect angle bracket (18), padlock and chain (19), chain hook (20), and handle (21) for breaks.Replace angle bracket (18), padlock and chain (19), chain hook (20), and handle (21) if broken.Inspect bars (24) and (27), and two clevises (25) for bends and breaks. Replace bars (24), (27) andclevises (25) if bent or broken.Inspect latch (26) for proper operation. Replace latch (26) if damaged.Inspect skin (22) for tears and punctures. Replace skin (22) if torn or punctured.Inspect frame (1) for breaks. Replace entire hinged roof if damaged.

5-524

TM 9-2320-272-24-4


5-525

TM 9-2320-272-24-4



chromate primer.l Apply sealing compound to exterior joints prior to installation.

l Apply adhesive to both rubber and metal surfaces.

l Perform step 1 only if skin was removed.l Assistant will help with step 1.

1. Install skin (7) on hinged roof frame (11) with one-hundred fifty-seven new rivets (8).

2. Install four new grommets (10) on hinged roof frame (11) with four screws (9).3. Install clevises (18) on bars (15) and (25) and position in slots of hinged roof frame (11).

4. Install latch (17) on hinged roof frame (11) with four washers (20) and nuts (21).

5. Install two clevises (18) on latch (17) with two pins (16) and new cotter pins (19).

6. Install new O-ring (36), new gasket (6), plate (5), and handle (3) on skin (7) with two screws (4).7. Install handle (3) on latch (17) with washer (22), nut (23), and new cotter pin (24).

8. Install angle bracket (37) on skin (7) with three screws (38).9. Install chain hook (1) and padlock and chain (2) on angle bracket (37).

10. Install new seals (31) and (33) on hinged roof frame (11).11. Install new seal (35) and retainer (34) on hinged roof frame (11) with fifty-two new rivets (32).

12. Install new cushion pads (12) and (27) on hinged roof frame (11).

13. Install new seal (28) and retainer (30) on hinged roof frame (11) with twenty-four new rivets (29).

14. Install new seal (13) and hinge (14) on hinged roof frame (11) with sixty-eight screws (26).

5-526

TM 9-2320-272-24-4


5-527

TM 9-2320-272-24-4


15. Install panel (18) on hinged roof frame (1) with forty-one screws (17).

16. Install panel (2) on hinged roof frame (1) with fifty-five screws (10).

17. Install molding (15) on panels (2) and (18) with two screws (16).

18. Install moldings (3), (23), and (24) on panels (2) and (18).

19. Install three fillers (22) on panels (2) and (18) with six screws (21).20. Install three bars (20) on fillers (22) with six screws (19).

21. Install plate (8) on panel (2) with six screws (9).22. Install cover (14) on panel (2) with ten screws (13).

23. Install handle (12) on panel (2) with four screws (11).

24. Install moldings (4), (6), and (7) on panels (2) and (18) with thirty screws (5).

25. Install three holder assemblies (26) on hinged roof frame (1) with six screws (25).

26. Install three clamps (28) on hinged roof frame (1) with twelve screws (27).

NOTEl Insulate entire structure with fibrous glass felt insulation.l Assistant will help with steps 15 and 16.

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TM 9-2320-272-24-4


5-529

TM 9-2320-272-24-4


1. Attach four chains to lifting device and hinged roof (1).

All personnel must stand clear during lifting operations. Aswinging or shifting load may cause injury to personnel.


2. Lift hinged roof (1) from supports and install on van body (6) with sixty-nine screws (5).3. Install two holding rods (4) and angle brackets (2) on hinged roof (1) with four screws (3).4. Remove chains from lifting device and hinged roof (1).

NOTEHinged roof-operated blackout circuit plungers must be installedbefore side blackout harnesses are installed in load center.

5. Install hinged roof-operated blackout circuit plungers (para. 3-377).

FOLLOW-ON TASKS: l Install ceiling filler and side panels (para. 5-79).l Install ceiling rear cover (para. 5-80).l Install left and right side blackout harness (para. 5-98).l Retract van body sides (TM 9-2320-272-10).

5-530

TM 9-2320-272-24-4

5-78. FRONT WALL REGISTERS REPLACEMENT


INITIAL SETUP:


TOOLS


General mechanic’s tool kit (Appendix E, Item 1)


NOTEAll four front wall registers are replaced the same way. Thisprocedure covers one register.

Remove four screws (2) and register (3) from front wall (1).

Install register (3) on front wall (1) with four screws (2).

5-531

TM 9-2320-272-24-4

5-79. CEILING FILLER AND SIDE PANELS REPLACEMENT


INITIAL SETUP:



MATERIALS/PARTSAdhesive (Appendix C, Item 7)Primer (Appendix C, Item 57)

PERSONNEL REQUIREDTWO


EQUIPMENT CONDITIONl Parking brake set (TM 9-2320-272-10).l Inside telephone jacks (ceiling) removed

(para. 3-374).l Blackout light switches and receptacles removed

(para. 3-373).l Ceiling deflectors and registers removed

(para. 5-83).l Blackout and emergency light fixtures removed

(para. 3-372).l Fluorescent light fixtures removed (para. 4-168).l Rear splice plate removed (para. 5-84).


NOTELeft and right ceiling filler and side panels are replaced the sameway. This procedure covers the left side.

a. Removal

1. Remove thirty screws (9) and side panel (8) from lintel (6), air ducts (5) and (7), and filler panel (1).

2. Remove seven screws (10) and filler panel (1) from filler angles (2) and (3) and transition (4).

3. Remove forty-four screws (14) and side panel (15) from lintel (6), rear header (13), and air ducts (11)and (12).


chromate primer.l Apply adhesive to both rubber and metal surfaces.

l Insulate entire structure with fibrous glass felt insulation.1. Install side panel (15) on lintel (6), rear header (13), and air ducts (12) and (11) with forty-four

screws (14).2. Install tiller panel (1) on filler angles (3) and (2) and transition (4) with seven screws (10).3. Install side panel (8) on lintel (6), air ducts (7) and (5), and filler panel (1) with thirty screws (9).

5-532

TM 9-2320-272-24-4

5-79. CEILING FILLER AND SIDE PANELS REPLACEMENT (Contd)

FOLLOW-ON TASKS: l Install rear splice plate (para. 5-84).l Install fluorescent light fixtures (para. 4-168).l Install blackout and emergency light fixtures (para. 3-372).l Install blackout light switches and receptacles (para. 3-373).l Install ceiling deflectors and registers (para. 5-83).l Install inside telephone jacks (ceiling) (para. 3-374).

5-533

TM 9-2320-272-24-4

5-80. CEILING REAR COVER REPLACEMENT


INlTlAL SETUP:



MATERIALS/PARTSAdhesive (Appendix C, Item 7)Primer (Appendix C, Item 57)

PERSONNEL REQUIREDTWO


EQUIPMENT CONDlTlONl Parking brake set (TM 9-2320-272-10).l Rear splice plate removed (par. 5-84).


Remove eight screws (4), thirteen screws (5), and rear cover (3) from rear head (2) and airduct (1).


chromate primer.

l Apply adhesive to metal surfaces.l Insulate entire structure with fibrous glass felt insulation.

1. Install rear cover (3) on rear header (2) with eight screws (4).2. Install rear cover (3) on air duct (1) with thirteen screws (5).

5-534

TM 9-2320-272-24-4

5-80. CEILING REAR COVER REPLACEMENT (Contd)

FOLLOW-ON TASK: Install rear splice plate (para. 5-84).

5-535

TM 9-2320-272-24-4

5-81. CEILING AIR DUCTS REPLACEMENT


INITlAL SETUP:


TOOLSTM 9-2320-272-24P


MATERIALS/PARTSl Parking brake set (TM 9-2320-272-10).

Primer (Appendix C, Item 57)l Van sides fully expanded and secured

(TM 9-2320-272-10).

PERSONNEL REQUIREDl Ceiling rear cover removed (para. 5-80).

TWOl Ceiling filler and side panels removed (para. 5-79).


1. Remove fifty-two screws (6) and two enclosures (7) from air ducts (3) and (5).2. Remove fourteen screws (4) from air ducts (3) and (5) and support (1).3. Remove forty-two screws (2) and air duct (3) from ceiling (9).4. Remove eighteen screws (8) and air duct (5) from ceiling (9).5. Remove nine screws (10) and support (1) from ceiling (9).6. Remove fifty-two screws (20) and two enclosures (19) from air ducts (17) and (21).7. Remove four screws (16) from air duct (17) and support (13).8. Remove six screws (18) from air duct (21) and support (13).9. Remove twenty-six screws (15) and air ducts (17) and (21) from ceiling (9).

10. Remove ten screws (14) and support (13) from ceiling (9).11. Remove seven screws (12) and support (11) from ceiling (9).

b. Installation

1. Install support (11) on ceiling (9) with seven screws (12).2. Install support (13) on ceiling (9) with ten screws (14).3. Install air ducts (17) and (21) on ceiling (9) with twenty-six screws (15).4. Install air duct (21) on support (13) with six screws (18).5. Install air duct (17) on support (13) with four screws (16).6. Install two enclosures (19) on air ducts (21) and (17) with fifty-two screws (20).7. Position support (1) over bow of roof frame and install on ceiling (9) with nine screws (10).8. Install air duct (5) on ceiling (9) with eighteen screws (8).9. Install air duct (3) on ceiling (9) with forty-two screws (2).

10. Install air ducts (3) and (5) on support (1) with fourteen screws (4).11. Install two enclosures (7) on air ducts (5) and (3) with fifty-two screws (6).

5-536

NOTEInsulate areas of dissimilar metal-to-metal contact with zincchromate primer.

TM 9-2320-272-24-4

5-81. CEILING AIR DUCTS REPLACEMENT (Contd)

FOLLOW-ON TASKS: l Install ceiling filler and side panels (para. 5-79).l Install ceiling rear cover (para. 5-80).l Retract van body sides (TM 9-2320-272-10).

5-537

TM 9-2320-272-24-4

5-82. CEILING TRANSITION MAINTENANCE

THIS TASK COVERS:a. Removalb. Disassembly

c. Assemblyd. Installation

INITIAL SETUP:


TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONRivet gun l Parking brake set (TM 9-2320-272-10).

MATERIALS/PARTSl Van sides fully expanded and secured

(TM 9-2320-272-10).Two seals, 15 in. (Appendix D, Item 617)Twenty-four rivets (Appendix D, Item 542)Two seals, 28 in. (Appendix D, Item 617)Adhesive (Appendix C, Item 7)

l Ceiling filler and side panels removed (para. 5-79).l Ceiling air ducts removed (para. 5-81).


a. Removal

1. Remove seven screws (4) from support (8).

NOTEAssistants will help with step 2.

2. Remove thirty screws (2) and transition (3) from ceiling (1).

1. Remove seven rivets (6), retainer (7), seal (5), and support (8) from transition (3). Discard rivets (6)and seal (5).

2. Remove ten rivets (18), two retainers (9), and seals (10) from transition (3). Discard seals (10) andrivets (18).

3. Remove seven rivets (16), retainer (17), and seal (15) from transition (3). Discard seal (15) andrivets (16).

4. Remove four screws (11) and filler angle (12) from transition (3).5. Remove three screws (13) and filler angle (14) from transition (3).

5-538

TM 9-2320-272-24-4

5-82. CEILING TRANSITION MAINTENANCE (Contd)

5-539

TM 9-2320-272-24-4


1. Install filler angle (14) on transition (3) with three screws (13).

2. Install tiller angle (12) on transition (3) with four screws (11).NOTE

Apply adhesive to both rubber and metal surfaces.

3. Install new seal (15) and retainer (17) on transition (3) with seven new rivets (16).4. Install two new seals (10) and retainers (9) on transition (3) with ten new rivets (18).5. Align support (8) with flanges on transition (3) and install support (8), new seal (5), and retainer (7)

on transition (3) with seven new rivets (6).

NOTEl Insulate inside of transition with duct lining insulation.l Assistants will help with steps 1 and 2.

1. Install transition (3) on ceiling (1) with thirty screws (2).2. Install support (8) on ceiling (1) with seven screws (4).

5-540

TM 9-2320-272-24-4


FOLLOW-ON TASKS: l Install ceiling air ducts (par. 5-81).l Install ceiling filler and side panels (para. 5-79).l Retract van body sides (TM 9-2320-272-10).

5-541

TM 9-2320-272-24-4

5-83. CEILING DEFLECTOR AND REGISTERS REPLACEMENT


INITIAL SETUP:


REFERENCES (TM)TM 9-2320-272-10

TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).

a. Removal

1. Remove twenty screws (3) and ten registers (4) from ceiling side panels (2) and deflectors (6).2. Remove one hundred screws (5) and ten deflectors (6) from air ducts (1) and ceiling side panels (2).

b. Installation

1. Install ten deflectors (6) on air ducts (1) and ceiling side panels (2) with one hundred screws (5).

2. Install ten registers (4) on ceiling side panels (2) and ten deflectors (6) with twenty screws (3).

5-542

b. Installation

a. Removal

TM 9-2320-272-24-4

5-84. REAR SPLICE PLATE REPLACEMENT


INITIAL SETUP:


TOOLS


General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).

NOTELeft and rear splice plates are replaced the same way. Thisprocedure covers the right side.

Remove four screws (4) and splice plate (3) from side panel (1) and rear cover (2).

Install splice plate (3) on side panel (1) and rear cover (2) with four screws (4).

5-543

a. Removal

TM 9-2320-272-24-4

5-85. BONNET FRAME PARTS REPLACEMENT

THIS TASK COVERS:


INITIAL SETUP:


TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1)Rivet gun

EQUIPMENT CONDITION

MATERIALS/PARTSInsulation (Appendix D, Item 260)Two speed nuts (Appendix D, Item 667)Eight rivets (Appendix D, Item 557)Thirty-five rivets (Appendix D, Item 556)One-hundred sixteen rivets (Appendix D,

l Parking brake set (TM 9-2320-272-10).l Bonnet control rod removed (para. 3-361).l Van heater removed (para. 3-379).l Air conditioner (if equipped) removed (para. 5-88).l Bonnet access door removed (para. 5-86).l Bonnet door removed (para. 5-87).

Item 547)One-hundred seventy-six rivets (Appendix D,

Item 542)Sixteen rivets (Appendix D, Item 559)Adhesive (Appendix C, Item 7)Primer (Appendix C, Item 57)Sealing compound (Appendix C, Item 67)

1. Remove twenty-seven screws (5) and drip molding (4) from bonnet frame (14).2. Remove seventeen screws (13) and door panel (12) from bonnet frame (14).

3. Remove four screws (15) and plate (1) from outer panel (2) and bonnet frame (14).4. Remove thirty-eight rivets (3), twenty-four rivets (7), and outer panels (6) and (2) from bonnet

frame (14) and bonnet lower panel (11). Discard rivets (3) and (7).

NOTEl Left and right fillers are removed the same way. This procedure

is for the left filler.


5. Remove sixty-four rivets (9), thirty-one rivets (10), bonnet lower panel (11), and two tillers (8) frombonnet frame (14). Discard rivets (9) and (10).

5-544

TM 9-2320-272-24-4

5-85. BONNET FRAME PARTS REPLACEMENT (Contd)

5-545

b. Installation

TM 9-2320-272-24-4


6.

7.

8.

9.

10.

11.

12.

NOTELeft and right heater duct assemblies are removed the same way.This procedure covers the right side.

Remove two fasteners (5) from support (14) and heater duct (2).

Remove four rivets (12) and two speed nuts (13) from support (14). Discard rivets (12) and speednuts (13).Remove three screws (11) and support (14) from front wall (15).Remove thirty-six rivets (3), heater duct (2), and insulation (4) from bonnet floor (19). Discardrivets (3) and insulation (4).Remove sixteen rivets (7), twenty-four rivets (8), thirty-six rivets (10), and inner panels (9) and (16)from bonnet frame (6) and bonnet floor (19). Discard rivets (7), (8), and (10).

Remove three screws (20) and post (1) from bonnet floor (19).


Remove forty-three rivets (17), thirty-five rivets (18), and bonnet floor (19) from bonnet frame (6)and front wall (15). Discard rivets (17) and (18).


chromate primer.l Apply sealing compound to exterior joints prior to installation.l Insulate all enclosed structure with fibrous glass felt insulation.l Assistant will help with step 1.

1. Install bonnet floor (19) on bonnet frame (6) and front wall (15) with forty-three new rivets (17) andthirty-five new rivets (18).

2. Install post (1) on bonnet floor (19) with three screws (20).

3. Install inner panels (9) and (16) on bonnet frame (6) and bonnet floor (19) with thirty-six newrivets (10), twenty-four new rivets (8), and sixteen new rivets (7).

NOTELeft and right heater duct assemblies are installed the same way.This procedure covers the right side.

4. Install new insulation (4) and heater duct (2) on bonnet floor (19) with thirty-six new rivets (3).5. Install support (14) on front wall (15) with three screws (11).

6. Install two new speed nuts (13) on support (14) with four new rivets (12).

7. Install heater duct (2) on support (14) with two fasteners (5).

5-546

TM 9-2320-272-24-4


5-547

TM 9-2320-272-24-4


8.

9.

10.

11.

12.

NOTEl Left and right fillers are installed the same way. The left filler

is shown.


Install two fillers (8) and bonnet lower panel (11) on bonnet frame (14) with sixty-four newrivets (9) and thirty-one new rivets (10).

Install outer panels (6) and (2) on bonnet frame (14) and bonnet lower panel (11) with twenty-fournew rivets (7) and thirty-eight new rivets (3).

Install plate (1) on outer panel (2) and bonnet frame (14) with four screws (15).

Install door panel (12) on bonnet frame (14) with seventeen screws (13).

Install drip molding (4) on bonnet frame (14) with twenty-seven screws (5).

FOLLOW-ON TASKS: l Install bonnet door (para. 5-87).l Install bonnet access door (para. 5-86).l Install van heater (para. 3-379).l Install air conditioner (if equipped) (para. 5-88)l Install bonnet control rod (para. 3-361).

5-548

a. Removal

TM 9-2320-272-24-4

5-86. BONNET ACCESS DOOR MAINTENANCE

THIS TASK COVERS:a. Removal d. Assemblyb. Disassembly e. Installationc. Cleaning and Inspection

INITIAL SETUP:



TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONRivet gun l Parking brake set (TM 9-2320-272-10).

MATERIALS/PARTSl Bonnet control rod removed (para. 3-361).

One hundred forty-eight rivets (Appendix D,Item 551)

Seal, 51 in. (Appendix D, Item 633)Seal (Appendix D, Item 623)Primer (Appendix C, Item 57)Sealing compound (Appendix C, Item 67)

NOTE

Assistant will help with step.

Remove twelve screws (1) and access door assembly (2) from bonnet frame (3).

5-549

b. Disassembly

c. Cleaning

d. Assembly

TM 9-2320-272-24-4

5-86. BONNET ACCESS DOOR MAINTENANCE (Contd)

1. Remove twelve screws (1), hinge (2), and seal (21) from door frame (17). Discard seal (21).2. Remove four screws (5) and two angle brackets (4) from inner panel (3).3. Remove four screws (7), rod (8), and holder bracket (6) from inner panel (3).4. Remove screw (11), two nuts (9), screws (12), and bracket (10) from inner panel (3).


5. Remove thirty-three nuts (13), screws (18), seventy-four rivets (19), outer panel (20), threeretainers (14), and seal (16) from door frame (17). Discard seal (16) and rivets (19).

NOTEPerform step 6 if inner panel is to be replaced (subtask c.).

6. Remove seventy-four rivets (15) and inner panel (3) from door frame (17). Discard rivets (15).

1. For general cleaning instructions, refer to para. 2-14.2. Inspect hinge (2) for breaks and proper operation. Replace hinge (2) if damaged.3. Inspect three retainers (14) for bends and breaks. Replace if bent or broken.4. Inspect angle brackets (4), holder bracket (6), and rod (8) for cracks and breaks. Replace if cracked

or broken.5. Inspect outer panel (20) for tears and punctures. Replace outer panel (20) if tom or punctured.6. Inspect inner panel (3) for tears and punctures. Replace inner panel (3) if torn or punctured.

7. Inspect door frame (17) for bend, cracks, and breaks. Replace door frame (17) if bent, cracked, orbroken.


chromate primer.l Apply sealing compound to exterior joints prior to installation.

l Insulate all enclosed structure with fibrous glass felt insulation.l Perform step 1 only if inner panel was removed.

l Assistant will help with steps 1 and 2.1. Install inner panel (3) on door frame (17) with seventy-four new rivets (15).2. Install new seal (16), three retainers (14), and outer panel (20) on door frame (17) with thirty-three

screws (18), nuts (13), and seventy-four new rivets (19).3. Install holder bracket (6) and rod (8) on inner panel (3) with four screws (7).

4. Install screw (11) and two nuts (9) on bracket (10).

NOTEAngle bracket can be installed on either side of door.

5. Install bracket (10) on inner panel (3) with two screws (12).

6. Install two angle brackets (4) on inner panel (3) with four screws (5).7. Install new seal (21) and hinge (2) on door frame (17) with twelve screws (1).

5-550

TM 9-2320-272-24-4


5-551

e. Installation

TM 9-2320-272-24-4



Install access door assembly (2) on bonnet frame (3) with twelve screws (1).

5-552

TM 9-2320-272-24-4


FOLLOW-ON TASK: Install bonnet control rod (para. 3-361).

5-553

a. Removal

TM 9-2320-272-24-4

5-87. BONNET DOOR MAINTENANCE

THIS TASK COVERS:



INITIAL SETUP:



MATERIALS/PARTSChannel seals (as required) (Appendix D,

Item 623)Forty-eight rivets (Appendix D, Item 547)Fifty-two rivets (Appendix D, Item 551)Seal, 78 in. (Appendix D, Item 605)Seal, 24 in. (Appendix D, Item 605)Seal, 27 in. (Appendix D, Item 633)Cork (Appendix C, Item 24)Primer (Appendix C, Item 57)Sealing compound (Appendix C, Item 67)



NOTELeft and right bonnet doors are replaced the same way. Thisprocedure covers the left side.

1. Remove two screws (4) and washers (5) from bonnet door (3) and bonnet (1).


2. Remove seven screws (2) and bonnet door (3) from bonnet (1).3. Position bonnet door (3) squarely on four jack stands with outer panel facing upwards.

5-554

5-87. BONNET

TM 9-2320-272-24-4

5-555

5-87. BONNET

TM 9-2320-272-24-4

1.

2.

3.4.

5.

6.

7.

8.

Remove six screws (16), spacer plate (15), seal (14), hinge (13), and seal (12) from frame (7). Discardseals (12) and (14).Remove eighteen nuts (28), screws (11), and two retainers (4) from outer panel (10), frame (7). andseal (3).


Remove seventeen rivets (9) and outer panel (10) from frame (7). Discard rivets (9).Remove twenty-four rivets (27), intake assembly (17), intake panel (26) (if present), and preformedcork (1) from inner panel (2). Discard rivets (27) and cork (1).Remove fourteen rivets (21), two channels (20), channel seals (19), and channels (18) from intakeassembly (17). Discard rivets (21) and channel seals (19).Remove ten rivets (22), two channels (23), channel seals (24), and channels (25) from intakeassembly (17). Discard rivets (22) and channel seals (24).Remove seven nuts (5), screws (8), retainer (6), and seal (3) from frame (7). Discard seal (3).


Remove thirty-three rivets (29), two rivets (30), and inner panel (2) from frame (7). Discardrivets (29) and (30).

5-556

5-87. BONNET

TM 9-2320-272-24-4

5-557

5.87. BONNET

TM 9-2320-272-24-4

1.2.

3.

4.

5.6.7.

8.

For general cleaning instructions, refer to para. 2-14.Inspect hinge (9) for breaks, corrosion, and proper operation. Replace hinge (9) if damaged.

Inspect retainers (8) and (5) and spacer plate (10) for bends and breaks. Replace retainers (8)and (5) and space plate (10) if bent or broken.Inspect outer panel (4) and inner panel (7) for tears, cracks, and punctures. Replace outer panel (4)and inner panel (7) if torn, cracked, or punctured.Inspect intake assembly (11) for cracks and bends. Replace intake assembly (11) if cracked or bent.

Inspect intake panel (3) for bends and breaks. Replace intake panel (3) if bent or broken.Inspect channels (12), (13), (1), and (2) for bends and breaks. Replace if bent or broken.

Inspect frame (6) for bends, breaks, cracks, and warpage. Replace entire bonnet door assembly ifframe (6) is damaged.

5-558

5-87. BONNET

TM 9-2320-272-24-4

5-559

5-87. BONNET

TM 9-2320-272-24-4


chromate primer.l Apply sealing compound to exterior joints prior to installation.l Insulate all enclosed structure with fibrous glass felt insulation.l Assistant will help with step 1.

1. Install inner panel (2) on frame (7) with thirty-three new rivets (29) and two new rivets (30).2. Install new seal (3) and retainer (6) on frame (7) with seven screws (8) and nuts (5).3. Install two new channel seals (24), channels (23), and channels (25) on intake assembly (17) with

ten new rivets (22).4. Install two new channel seals (19), channels (18), and channels (20) on intake assembly (17) with

fourteen new rivets (21).


5. Install new preformed cork (1), intake panel (26) (if present), and intake assembly (17) on innerpanel (2) with twenty-four new rivets (27).

6. Install outer panel (10) on frame (7) with seventeen new rivets (9).7. Install two retainers (4) in seal (3) with eighteen screws (11) and nuts (28).

8. Install new seal (12), hinge (13), spacer plate (15), and new seal (14) on frame (7) with six screws (16).Ensure hinge is flush with top of door.

5-560

5-87. BONNET

TM 9-2320-272-24-4

5-561

5-87. BONNET

TM 9-2320-272-24-4


Install bonnet door (3) on bonnet (1) with seven screws (2), two screws (4), and washers (5).

5-562

5-88. AIR

TM 9-2320-272-24-4


APPLICATION MODELS EQUIPMENT CONDITIONM934/A1/A2 l Parking brake set (TM 9-2320-272-10).

l Cab tarpaulin and bows removedTOOLS (TM 9-2320-272-10).General mechanic’s tool kit (Appendix E, Item 1)ChainLifting device

l Windshield lowered (TM 9-2320-272-10).l Companion seat lowered (TM 9-2320-272-10).l External power source disconnected

MATERIALS/PARTS(TM 9-2320-272-10).

Cotter pin (Appendix D, Item 57)Two lockwashers (Appendix D, Item 418)

l Battery ground cables disconnected (para. 3-126).l Air conditioner drain tube removed (para. 3-382).l Bonnet door removed (para. 5-87).

REFERENCES (TM)TM 9-2320-272-10

GENERAL SAFETY INSTRUCTIONSAll personnel must stand clear during lifting

TM 9-2320-272-24P operations.

NOTEScrew quantity for steps 1, 2, and 4 may differ from vehicle tovehicle. Record quantity removed for installation.

1. Remove sixteen screws (6) and lower angle bracket (5) from lower panel mounting angle (7).2. Remove twelve screws (9) and lower panel mounting angle (7) from bonnet (11).3. Remove four screws (8) and two mounting angles (4) from bonnet (11).4. Remove fourteen screws (3), snap (2), and condenser guard (1) from air conditioner (10).

5-563

5-88. AIR

TM 9-2320-272-24-4

5. Remove sixteen screws (1) and top enclosure (2) from bonnet (8) and air conditioner (7).

6. Remove twelve screws (4) and right enclosure (3) from bonnet (8) and air conditioner (7).

7. Remove four screws (14), plate (13), and bellows (12) from left enclosure (11).

8. Remove ten screws (9) and left enclosure (11) from bonnet (8) and air conditioner (7).

9. Remove cotter pin (16) and door rod (10) from swing arm (15). Discard cotter pin (16).10. Remove seven screws (6) and bottom enclosure (5) from bonnet (8) and air conditioner (7).11. Disconnect power cable (24) from air conditioner (7).

12. Remove screw (26), ground cable (27), and lockwasher (25) from air conditioner (7). Discardlockwasher (25).

13. Remove screw (23), ground cable (27), and lockwasher (28) from mounting plate (18) and bonnetfloor (29). Discard lockwasher (28).

14. Remove five screws (22) from mounting plate (18) and bonnet floor (29).15. Remove six screws (21) from mounting plate (17) and bonnet floor (29).

WARNING

All personnel must stand clear during lifting operations.A snapped cable, or swinging or shifting load may resultin injury or death to personnel.

NOTETwo assistants will help with step 16.

16. Attach chains to lifting device and four lifting brackets (20) on air conditioner (7) and remove airconditioner (7) from bonnet (8). Position air conditioner (7) for access to bottom of unit.

17. Remove six screws (19) and mounting plates (17) and (18) from air conditioner (7).

1.

2.

3.

4.

5.

Two assistants will help with step 2.

Attach chains to lifting device and four lifting brackets (20).

Position air conditioner (7) in bonnet (8).

Install mounting plate (17) on bonnet floor (29) with six screws (21).Install ground cable (27) on mounting plate (18) and bonnet floor (29) with new lockwasher (28),and screw (23).

6. Install ground cable (27) on air conditioner (7) with new lockwasher (25), and screw (26).

7. Install mounting plate (18) on bonnet floor (29) with five screws (22).

8. Connect power cable (24) to air conditioner (7).

9. Remove lifting device and chains from air conditioner (7).

Install mounting plates (17) and (18) on air conditioner (7) with six screws (19).

WARNING

All personnel must stand clear during lifting operations.A snapped cable, or swinging or shifting load may resultin injury or death to personnel.

NOTE

5-564

5-88. AIR

TM 9-2320-272-24-4

5-565

5-88. AIR

TM 9-2320-272-24-4

10. Install bottom enclosure (5) on bonnet (7) and air conditioner (8) with seven screws (6).

11. Install door rod (9) on swing arm (15) with new cotter pin (16).

12. Install left enclosure (10) on bonnet (7) and air conditioner (8) with ten screws (11). Ensure doorrod (9) is positioned through bellows (12).

13. Install bellows (12) on left enclosure (10) with plate (13) and four screws (14).

14. Install right enclosure (3) on bonnet (7) and air conditioner (8) with twelve screws (4).

15. Install top enclosure (2) on bonnet (7) and air conditioner (8) with sixteen screws (1).

5-566

5-88. AIR

TM 9-2320-272-24-4

NOTEScrew quantity for steps 16, 18, and 19 may differ from vehicle tovehicle. Install screws as recorded.

16. Install condenser guard (17) on air conditioner (8) with snap (18) and fourteen screws (19).17. Install two mounting angles (22) on bonnet (7) with four screws (24).18. Install lower panel mounting angle (23) on bonnet (7) with twelve screws (25).19. Install lower angle bracket (21) on bonnet (7) and two mounting angles (22) with sixteen screws (20).

FOLLOW-ON TASKS: l Install bonnet door (para. 5-87).l Install air conditioner drain tube (para. 3-382).l Connect battery ground cables (para. 3-126).l Connect external power source (TM 9-2320-272-10).l Raise companion seat (TM 9-2320-272-10).l Raise windshield (TM 9-2320-272-10).l Install cab tarpaulin and bows (TM 9-2320-272-10).

5-567

5-89. MAIN

TM 9-2320-272-24-4


INITIAL SETUP:


EQUIPMENT CONDITION



l Parking brake set (TM 9-2320-272-10).l Battery ground cables disconnected (para 3-126).l Fluorescent light tubes removed (para 3-371).l Emergency/blackout lamp and light removed

(para 3-372).l Blackout light switch and 110-volt receptacle

removed (para 3-373).

NOTEl The left and right main wiring harnesses are replaced the same

way. This procedure covers the right main wiring harness.l Tag wires for installation.

1. Remove six screws (1) and cover (2) from load center (8).2. Remove three setscrews (9) and wires (3) from relay (10).

3. Remove setscrew (15) and wire (16) from neutral bus (11).4. Remove three screws (13) and five wires (14) from 20 amp circuit breakers (12).5. Remove screw (4) and clamp (5) from plate (7) and wiring harnesses (6).6. Remove twelve screws (22) and clamps (21) from van ceiling (18) and main wiring harness (20).7. Remove grommet (23) from van side panel (17).

8. Remove three screws (25) and wire clip (24) from van side panel (17).

9. Remove main wiring harness (20) from van body (19).

1. Position main wiring harness (20) on van body (19).2. Install wire clip (24) on side panel (17) of van body (19) with three screws (25).

3. Install grommet (23) on side panel (17).

4. Install twelve clamps (21) on main wiring harness (20) and van ceiling (18) with twelve screws (22).

5. Install clamp (5) on harnesses (6) and plate (7) with screw (4).

6. Install five wires (14) on 20 amp circuit breakers (12) with three screws (13).

7. Install wire (16) on neutral bus (11) with setscrew (15).

8. Install three wires (3) on relay (10) with three setscrews (9).

9. Install cover (2) on load center (8) with six screws (1).

5-568

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l Install blackout light switch and 110-volt receptacle (para. 3-373l Install emergency/blackout lamp and light (para. 3-372).l Install fluorescent light tubes (para. 3-371).l Connect battery ground cables (para. 3-126).

5-569

5-90. VAN

TM 9-2320-272-24-4


INITIAL SETUP:

APPLICABLE MODELM934/A1/A2


TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONl Parking brake set (TM 9-2320-272-10)l Battery ground cables disconnected (para. 3-126).l Ceiling filler and side panels removed (para. 5-79).

NOTETag cables for installation.

1. Remove twelve screws (4) and clamps (5) from wiring harness (6) and van ceiling (1).2. Disconnect plug (2) from air conditioner (3).3. Remove six screws (22) and cover (21) from load center (16).4. Remove screw (7) and clamp (8) from wiring harnesses (20) and (23) and plate (12).5. Remove nut (9), screw (15), two washers (10), cable assembly (14), ground cable (13), and wiring

harness cable (11) from load center (16).6. Remove three screws (19) and wiring harness cables (18) from 30 amp circuit breaker (17).

7. Remove wiring harness (20) from load center (16).

1. Position wiring harness (20) on load center (16).2. Install three wiring harness cables (18) on 30 amp circuit breaker (17) with three screws (19).

3. Install wiring harness cable (11), ground cable (13), and cable assembly (14) on load center (16) withscrew (15), two washers (10), and nut (9).

4. Install clamp (8) on wiring harnesses (23) and (20) and plate (12) with screw (7).

5. Install cover (21) on load center (16) with six screws (22).

6. Connect plug (2) to air conditioner (3).7. Install twelve clamps (5) on wiring harness (6) and van ceiling (1) with twelve screws (4).

5-570

5-90. VAN

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l Install ceiling filler and side panels (para. 5-79).l Connect battery ground cables (para. 3-126).

5-571

5-91. VAN

TM 9-2320-272-24-4


INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDITION

M934/A1/A2



l Parking brake set (TM 9-2320-272-10)l Battery ground cables disconnected (para. 3-126).l Ceiling filler and side panels removed (para. 5-79).

NOTETag wires for installation.

1. Remove twelve screws (6) and clamps (7) from van ceiling (1) and wiring harness (5).

2. Remove two grommets (3) from van ceiling (1) and wiring harness (5).3. Disconnect two plugs (2) from heater (4).

5-572

TM 9-2320-272-24-4

5-91. VAN HEATER WIRING HARNESS REPLACEMENT (Contd)

5-573

TM 9-2320-272-24-4


4. Remove thermostat cover (5) from thermostat (6).5. Remove four screws (4) and thermostat (6) from control center box (9).

6. Remove two screws (2) and wires (3) from control center box (9).7. Remove four screws (7) and upper cover (1) from control center box (9).

8. Remove six screws (17) and cover (16) from load center (12).9. Remove screw (10) and clamp (11) from wiring harnesses (18).

10. Remove setscrew (14), screw (13), and two wires (15) from load center (12).11. Remove wiring harnesses (18) from van body (8).

b. Installation

1. Position wiring harness (18) on van body (8) and install two wires (15) on load center (12) withscrew (13) and setscrew (14).

2. Place clamp (11) on wiring harnesses (18) and install on load center (12) with screw (10).3. Install cover (16) on load center (12) with six screws (17).4. Install upper cover (1) on center control box (9) with four screws (7).5. Install two wires (3) on thermostat (6) with two screws (2).

6. Install thermostat (6) on upper cover (1) with two screws (4).7. Install thermostat cover (5) on thermostat (6).

5-574

TM 9-2320-272-24-4


5-575

TM 9-2320-272-24-4


8. Connect two plugs (2) to heater (4).

9. Install two grommets (3) on wiring harness (5) and van ceiling (1).

10. Install twelve clamps (7) on wiring harness (5) and van ceiling (1) with twelve screws (6).

5-576

TM 9-2320-272-24-4



5-577

TM 9-2320-272-24-4

5-92. ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT


INITIAL SETUP:


TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONElectrical tool kit (Appendix E, Item 40) l Parking brake set (TM 9-2320-272-10).

l Battery ground cables disconnected (para. 3-126).l Ceiling filter and side panels removed (para. 5-79).

a. Removal


1. Remove twelve screws (28) and clamps (27) from van ceiling (25) and wiring harness (26).2. Remove grommet (24) from van ceiling (25) and wiring harness (26).

3. Remove wires (29) and (23) from heater (30).4. Remove thermostat cover (4) from thermostat (5).5. Remove two screws (3) and thermostat (5) from upper cover (7).6. Remove three insulated wire splicers (6) from wiring harness (8) and thermostat leads (2). Discard

insulated wire splicers (6).7. Remove four screws (1) and upper cover (7) from control center box (10).8. Remove six screws (22) and cover (11) from load center (15).9. Remove screw (12), clamp (13), and wiring harnesses (21) and (8) from load center (15).

10. Remove screw (20) and wire (19) from neutral bus (14).11. Remove three screws (17) and wires (18) from 20 amp circuit breakers (16).

12. Remove wiring harness (8) from van body (9).

b. Installation

1. Position wiring harness (8) on van body (9).

2. Install three wires (18) on 20 amp circuit breakers (16) with three screws (17).

3. Install wire (19) on neutral bus (14) with screw (20).

4. Install clamp (13) on wiring harnesses (8) and (21) and load center (15) with screw (12).

5. Install cover (11) on load center (15) with six screws (22).6. Install upper cover (7) on control center box (10) with four screws (1).7. Connect thermostat leads (2) to wiring harness (8) with three new insulated wire splicers (6).

8. Install thermostat (5) on upper cover (7) with two screws (3).9. Install thermostat cover (4) on thermostat (5).

10. Install wires (23) and (29) on heater (30).

5-578

TM 9-2320-272-24-4

5-92. ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT (Contd)

11. Install grommet (24) on wiring harness (26) and van ceiling (25).

12. Install twelve clamps (27) on wiring harness (26) and van ceiling (25) with twelve screws (28).


5-579

TM 9-2320-272-24-4

5-93. BLACKOUT BYPASS WIRING HARNESS MAINTENANCE

THIS TASK COVERS:

a. Removalb. Repair

c. Installation

INITIAL SETUP:


TOOLSTM 9-2320-272-24P

General mechanic’s tool kit (Appendix E, Item 1) EQUIPMENT CONDITIONl Parking brake set (TM 9-2320-272-10).l Battery ground cabled disconnected (para. 3-126)

a. Removal

NOTETag wires for installation

1. Remove six screws (1) and cover (2) from load center (6).

2. Remove two setscrews (10) and wires (3) from 3-pole circuit breaker (5).

3. Remove screw (8) and wire (9) from 30 amp circuit breaker (7).4. Remove two screws (13) and cover (14) from switch (11).5. Remove two screws (12) and switch (11) from van body (16).6. Loosen three screws (15) and remove wires (3) from switch (11).7. Remove wiring harness (4) from van body (16).

b. Repair

For wiring harness repair, refer to para. 3-131.

c. Installation

1. Position wiring harness (4) on van body (16).2. Install three wires (3) on switch (11) and tighten three screws (15).3. Install switch (11) on van body (16) with two screws (12).

4. Install cover (14) on switch (11) with two screws (13).

5. Install wire (9) on 30 amp circuit breaker (7) with screw (8).

6. Install two wires (3) on 3-pole circuit breaker (5) with two setscrews (10).7. Install cover (2) on load center (6) with six screws (1).

5-580

TM 9-2320-272-24-4

5-93. BLACKOUT BYPASS WIRING HARNESS MAINTENANCE (Contd)

FOLLOW-ON TASK: Connect battery ground cables (para. 3-126).

5-581

TM 9-2320-272-24-4

5-94. EMERGENCY LAMP WIRING HARNESS REPLACEMENT


INITIAL SETUP:



MATERIALS/PARTS


EQUIPMENT CONDITIONl Parking brake set (TM 9-2320-272-10).l Battery ground cables disconnected (para. 3-126).l Ceiling filter and side panels removed (para. 5-79).Locknut (Appendix D, Item 294)

1. Remove twelve screws (16) and clamps (15) from van ceiling (13) and wiring harness (14).2. Remove two screws (6) and cover (5) from switch (8).

3. Remove two screws (7) and switch (8) from switch box (10).

4. Disconnect two wires (4) and wire (9) from switch (8).

5. Remove four screws (3) and box (10) from van wall (2).

6. Remove grommet (1) from switch box (10).

7. Disconnect emergency lamp wiring harness lead (11) from emergency lamp wiring harness lead (12).8. Remove twelve screws (16) and clamps (15) from wiring harness (17) in van ceiling (13).

9. Remove grommet (18) and wiring harness (17) from van ceiling (13).


5-582

TM 9-2320-272-24-4

5-94. EMERGENCY LAMP WIRING HARNESS REPLACEMENT (Contd)

5-583

TM 9-2320-272-24-4


10. Disconnect lead (2) from circuit breaker (1).11. Remove two screws (5) and clamps (4) from wiring harness (3) and van body (12).12. Remove two screws (11) and clamps (6) from wiring harness (3) and van body (12).

13. Remove locknut (8), screw (10), clamp (9), and wiring harness (3) from spare tire carrier bracket (7).Discard locknut (8).

14. Remove nut (13) and wire (15) from positive battery terminal (14).

b. Installation

1. Install wire (15) on positive battery terminal (14) with nut (13).2. Install wiring harness (3) on spare tire carrier bracket (7) with clamp (9), screw (10), and new

locknut (8).3. Install two clamps (6) on wiring harness (3) and van body (12) with two screws (11).

4. Install two clamps (4) on wiring harness (3) and van body (12) with two screws (5).5. Connect lead (2) to circuit breaker (1).

5-584

TM 9-2320-272-24-4


5-585

TM 9-2320-272-24-4


6.7.8.

9.10.11.12.13.14.

Install grommet (5) on van ceiling (1) and wiring harness (2).

Install twelve clamps (3) on van ceiling (1) and wiring harness (2) with twelve screws (4).Connect emergency lamp wiring harness (14) to emergency lamp wiring harness lead (15).

Install grommet (17) on switch box (13).Install two cables (7) and cable (12) on switch (11).Install switch box (13) on van wall (6) with four screws (16).Install switch (11) on switch box (13) with two screws (10).Install cover (9) on switch (11) with two screws (8).Install emergency lamp wiring harness (18) on van ceiling (1) with twelve clamps (19) and screws (20).

5-586

TM 9-2320-272-24-4



5-587

TM 9-2320-272-24-4

5-95. BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT


INITIAL SETUP:


TOOLS

EQUIPMENT CONDITIONl Parking brake set (TM 9-2320-272-10Xl Main power switch off (TM 9-2320-272-10).l Clearance and blackout marker lights removed

General mechanic’s tool kit (Appendix E, Item 1) (para. 4-166).

REFERENCES (TM)l Rear wall interior panels removed (para. 5-74).l Ceiling filler and side panels removed (para. 5-79).l Ceiling air ducts removed (para. 5-81). l Battery ground cables disconnected (para. 3-126).

TM 9-2320-272- 10TM 9-2320-272-24P

a. Removal


1. Remove grommet (2) from van body (3) and wiring harness (1).

2. Remove two screws (6) and clamps (7) from van body (3) and wiring harness (1).3. Disconnect two wiring harness connectors (4) from rear wiring harness connectors (5).4. Remove twelve screws (11) and clamps (12) from van ceiling (13) and wiring harness (1).5. Remove five screws (10) and clamps (9) from van ceiling (13) and wiring harness (1).6. Remove four grommets (8) from van ceiling (13) and wiring harness (1).7. Remove wiring harness (1) from van body (14).

b. Installation

1. Position wiring harness (1) on van body (14) and install four grommets (8) on van ceiling (13) andwiring harness (1).

2. Install five clamps (9) on van ceiling (13) and wiring harness (1) with five screws (10).3. Install twelve clamps (12) on van ceiling (13) and wiring harness (1) with twelve screws (11).4. Connect two wiring harness connectors (4) to rear wiring harness connectors (5).5. Install two clamps (7) on wiring harness (1) and van body (3) with two screws (6).

6. Install grommet (2) on wiring harness (1) and van body (3).

5-588

TM 9-2320-272-24-4

5-95. BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT (Contd)

FOLLOW-ON TASKS: l Install ceiling air ducts (para. 5-81).l Install ceiling filler and side panels (para. 5-79).l Install clearance and blackout marker lights (para. 4-166).l Install rear wall interior panels (para. 5-74).l Connect battery ground cables (para. 3-126).l Main power switch on (TM 9-2320-272-10).

5-589

TM 9-2320-272-24-4

5-96. 400 HZ SUPPLY WIRING HARNESS REPLACEMENT


INITIAL SETUP:


TOOLSTM 9-2320-272-24P


MATERIALS/PARTSl Parking brake set (TM 9-2320-272-10).

Sealing compound (Appendix C, Item 62)l Battery ground cables disconnected (para. 3-126).l Ceiling filter and side panels removed (para. 5-79).

a. Removal


1. Remove four screws (1) and upper cover (2) from control center box (10).2. Remove four screws (5) and lower cover (4) from control center box (10).3. Remove screw (11) and wire (8) from terminal (9).4. Remove three screws (3) and wires (7) from circuit breaker (6).

5-590

TM 9-2320-272-24-4

5-96. 400 HZ SUPPLY WIRING HARNESS REPLACEMENT (Contd)

5-591

TM 9-2320-272-24-4

5-96. 400 HZ SUPPLY WIRING HARNESS REPLACEMENT (Contd)

5. Disconnect cables (13) and (12) from connectors (14) and (10).6. Remove eight screws (11) and electrical connector box cover (15) from electrical connector box (16).7. Disconnect four wires (7) from connector (14).8. Remove six screws (9) and cover (1) from load center (5).9. Remove screw (2) and clamp (3) from harnesses (4) and (8) and load center (5).

10. Pull wiring harness (8) out of coupling (6) and remove from load center (5) and electrical connectorbox (16).

b. Installation

6. Connect cables (13) and (12) to connectors (10) and (14).

1. Push wiring harness (8) through coupling (6), electrical connector box (16), and load center (5).2. Connect four wires (7) to connector (14).3. Install clamp (3) on harnesses (4) and (8) and load center (5) with screw (2).4. Install cover (1) on load center (5) with six screws (9).5. Apply sealing compound to screws (11) and install electrical connector box cover (15) on electrical

connector box (16) with eight screws (11).

5-592

5-96. 400 HZ

TM 9-2320-272-24-4

5-593

TM 9-2320-272-24-4

7. Install three wires (7) on circuit breaker (6) with three screws (3).8. Install wire (8) on terminal (9) with screw (11).9. Install lower cover (4) on control center box (10) with four screws (5).

10. Install upper cover (2) on control center box (10) with four screws (1).

5-594

5-96. 400 HZ

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install ceiling filler and side panels (para. 5-79).Connect battery ground cables (para. 3-126).

5-595

5-97. BRANCHED

TM 9-2320-272-24-4

THIS TASK COVERS:a. Removal b . Ins ta l la t ion

INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDITIONM934/A1/A2

TOOLS

Parking brake set (TM 9-2320-272-10).Battery ground cables disconnected (para. 3-126).Ceiling filter and side panels removed (para. 5-79).

General mechanic’s tool kit (Appendix E, Item 1)



1. Remove four screws (1) and upper cover (2) from control center box (6).2. Remove two screws (3) and wires (4) from terminal (5).3. Remove six screws (10) and clamps (9) from branched 400 Hz receptacle harness (8) and van

ceiling (7).

1. Install 400 Hz branched receptacle harness (8) on van ceiling (7) with six clamps (9) and screws (10).

2. Install two wires (4) on terminal (5) with two screws (3).3. Install upper cover (2) on control center box (6) with four screws (1).

5-596

5-97. BRANCHED

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install ceiling filler and side panels (para. 5-79).Connect battery ground cables (para. 3-126).

5-597

5-98. RIGHT

TM 9-2320-272-24-4

THIS TASK COVERS:a. Removal c. Installationb. Repair

INITIAL SETUP:


TOOLS

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Van body sides fully expanded and secured(TM 9-2320-272-10).

General mechanic’s tool kit (Appendix E, Item 1) Hinged roof-operated blackout circuit plungers

REFERENCES (TM)removed (para. 3-377).

TM 9-2320-272-10TM 9-2320-272-24P


1. Remove six screws (20) and cover (19) from load center (16).2. Remove screw (14) and wire (13) from neutral bus (15).

3. Remove screw (10) and wire (11) from relay (12).

4. Remove screws (5) and (9) and wires (7) and (8) from rear door blackout switch (6).NOTE

Perform steps 5 through 7 for left and right side of van body.5. Remove six screws (24), cover (22), and grommet (4) from van body (26).6. Remove nut (21), two screws (17), and two connector halves (18) from harness (23) and cover (22).

7. Remove nut (3), two screws (25), and two connector halves (1) from harness (23) and ceilingtruss (2) and pull harness (23) through hole in ceiling truss (2).

5-598

5-98. RIGHT

TM 9-2320-272-24-4

5-599

5-98. RIGHT

TM 9-2320-272-24-4

For wiring harness repair, refer to para. 3-131.

1. Push harness (23) in through hole in ceiling truss (2) and position on load center (15).

5-600

5-98. RIGHT

TM 9-2320-272-24-4

NOTE

Perform steps 2 through 5 for left and right side of van body.

2. Install two connector halves (1) on harness (23) and ceiling truss (2) with nut (3) and twoscrews (25).

3. Install cover (22) on van body (26) with six screws (241.4. Install two connector halves (18) on harness (23) and cover (22) with nut (19) and two screws (17).5. Install grommet (4) on van body (26).6. Install wires (7) and (8) on rear door blackout switch (6) with screws (5) and (9).7. Install wire (11) on relay (12) with screw (10).8. Install wire (13) on neutral bus (16) with screw (14).9. Install cover (20) on load center (15) with six screws (21).

FOLLOW-ON TASKS: Install hinged roof-operated blackout circuit plungers (para. 3-377).Retract van body sides (TM 9-2320-272-10).

5-601

5.99 TELEPHONE

TM 9-2320-272-24-4

THIS TASK COVERS:a. Removal b . Ins ta l la t ion

INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDITIONSM934/A1/A2 Parking brake set (TM 9-2320-272-10).

TOOLSInside telephone jacks removed (para. 3-374).

Gal mechanic’s tool kit (Appendix E, Item 1)Ceiling filler and side panels removed (para. 5-79).



1. Remove six screws (4) and clamps (3) from wiring harness (2) and van ceiling (1).

2. Remove wiring harness (2) from van body (5).

1. Install wiring harness (2) on van body (5).

2. Install wiring harness (2) on van ceiling (1) with six clamps (3) and screws (4).

5-602

5-99. TELEPHONE

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install ceiling filler and side panels (para. 5-79).Install inside telephone jacks (para. 3-374).

5-603

5-100. 3 PHASE

TM 9-2320-272-24-4

THIS TASK COVERS:a . Remova l b . Ins ta l la t ion

INITIAL SETUP:

APPLICABLE MODELS EQUIPMENT CONDITIONM934/A1/A2 Parking brake set (TM 9-2320-272-10).

TOOLSBattery ground cables disconnected (para. 3-126).

General mechanic’s tool kit (Appendix E, Item 1)Ceiling filter and side panels removed (para. 5-79).

REFERENCES (TM)TM 9-2320-272-10TM 9-2320272-24P


1. Remove six screws (1) and cover (12) from load center (5).

2. Remove screw (3) and clamp (13) from wiring harness (2) and van body (4).3. Remove screw (8) and wire (6) from neutral bus (7).

4. Remove three screws (10) and wires (11) from circuit breakers (9).5. Remove twelve screws (16) and clamps (15) from van ceiling (14) and wiring harness (2).6. Remove wiring harness (2) from van body (4).

1. Position wiring harness (2) on van body (4).2. Install wiring harness (2) on van ceiling (14) with twelve clamps (15) and screws (16).

3. Install three wires (11) on circuit breakers (9) with three screws (10).

4. Install wire (6) on neutral bus (7) with screw (8).5. Install clamp (13) on wiring harness (2) and van body (4) with screw (3).6. Install cover (12) on load center (5) with six screws (1).

5-604

TM 9-2320-272-24-4

FOLLOW-&TASKS: Install ceiling filler and side panels (para. 5-79).Connect battery ground cables (para. 3-126).

5-605

5-101. WINCH,

5-102. BOOM

TM 9-2320-272-24-4

Section VII. WINCH, HOIST, AND POWER TAKEOFF MAINTENANCE

PARA.NO. TITLE PAGE

NO.

5-102. Boom Elevating Cylinder Repair 5-6065-103. Boom Elevating Cylinder Packing Replacement 5-6105-104. Dump Roller Arm Maintenance 5-612

5-105. Dump Hoist Cylinder Maintenance 5-6145-106. Boom Extension Cylinder Repair 5-626

5-107. Crane Swinger Gearcase Repair 5-6305-108. Crane Control Valve Repair 5-636

THIS TASK COVERS:

a. Disassembly c. Assemblyb. Cleaning, Inspection, and Repair

INITIAL SETUP:


SPECIAL TOOLSBushing installer (Appendix E, Item 23)Handle (Appendix E, Item 61)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Spanner wrench (Appendix E, Item 166)

MATERIALS/PARTSPiston seal (Appendix D, Item 519)Rod seal (Appendix D, Item 560)O-ring (Appendix D, Item 465)Lockwire (Appendix D, Item 420)Wiper strip (Appendix D, Item 720)Packing (Appendix D, Item 510)

MATERIALS/PARTS (CONTD)Crocus cloth (Appendix C, Item 20)Lint-free cloth (Appendix C, Item 21)Drycleaning solvent (Appendix C, Item 71)


EQUIPMENT CONDITION• Parking brake set (TM 9-2320-272-10).• Boom elevating cylinder removed (para. 4-193)

GENERAL SAFETY INSTRUCTIONSKeep fire extinguisher nearby when usingdrycleaning solvent.Drycleaning solvent is flammable. Do not usenear open flame.

1. Using spanner wrench, remove cylinder head (2) from elevating cylinder body (3).

2. Remove piston rod (1) from elevating cylinder body (3).3. Remove lockwire (17), nut (18), washer (16), retainer (15), seal (14), piston (13), rod seal (5), cylinder

head (2), and wiper strip (8) from piston rod (1). Discard lockwire (17), piston seal (14), rod seal (5),and wiper strip (8).

5-606

5-102. BOOM

TM 9-2320-272-24-4

4. Remove packing nut (9), packing (10), bushing (11), and O-ring (12) from cylinder head (2). DiscardO-ring (12) and packing (10).

5. Remove two half rings (4) from piston (13).

6. Remove sleeve (7) from piston rod (1).7. Remove two lubrication fittings (6) from cylinder body (3) and piston rod (1).

5-607

5-102. BOOM

TM 9-2320-272-24-4

WARNING

Drycleaning solvent is flammable and will not be used near openflame. Use only in well-ventilated places. Failure to do this mayresult in injury to personnel.

1. Clean all parts of elevating cylinder with drycleaning solvent and dry with lint-free cloth.2. Inspect piston rod (9) for burrs, scoring, scratches, and stripped threads. If minor scratches and

burrs are present, remove with crocus cloth.3. If piston rod (9) is scored, scratched, or if stripped threads are evident, replace piston rod (9).4. Inspect piston (13) and cylinder body (1) for scoring. If piston (13) is scored, replace. If cylinder

body (1) is scored, replace elevating cylinder.

1. Install two lubrication fittings (2) in cylinder body (1) and piston rod (9).2. Install sleeve (10) in piston rod (9).3. Install two half rings (3) on piston (13).4. Install piston rod bushing (6) in cylinder head (5) with bushing installer and handle.

5. Install new O-ring (4), new packing (7), packing nut (8), and new wiper strip (11) on cylinder head (5).CAUTION

Be careful not to damage wiper strip when passing over threadson piston rod.

6. Install cylinder head (5) on piston rod (9).7. Install new rod seal (12), piston (13), new seal (14), retainer (15), and washer (16) on piston rod (9).8. Install nut (18) on piston rod (9) and secure nut (18) with lockwire (17).9. Slide piston rod (9) into cylinder body (1) and install cylinder head (5) on cylinder body (1).

10. Using spanner wrench, tighten cylinder head (5).

5-608

5-102. BOOM

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install boom elevating cylinder (para. 4-193).Lubricate elevating cylinder (LO 9-2320-272-12).

5-609

5-103. BOOM

TM 9-2320-272-24-4

THIS TASK COVERS:

a . Remova l b . Ins ta l la t ion

INITIAL SETUP:


REFERENCES (TM)LO 9-2320-272-12TM 9-2320-272-10TM 9-2320-272-24PSPECIAL TOOLS

Spanner wrench (Appendix E, Item 167)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Boom lifting device

MATERIALS/PARTSPacking (Appendix D, Item 510)GAA grease (Appendix C, Item 28)

EQUIPMENT CONDITIONParking brake set (TM 9-2320-272-10).Boom lowered (TM 9-2320-272-10).


WARNING

All personnel must stand clear during lifting operations. Asnapped cable, or shifting or swinging load ,may cause injury topersonnel.

1. Place wrecker boom (2) cylinder control lever (7) in UP position.2. Raise wrecker boom (2) with lifting device and install shipper braces (TM 9-2320-272-10).3. Place boom cylinder control lever (7) in LOWER position to release pressure from elevating cylinder (6).

4. Using spanner wrench, loosen packing nut (3) from cylinder head (5).

5. Slide nut (3) up on piston rod (1) to expose packing (4).CAUTION

Use care not to scratch piston rod surface when removing packing.6. Slide packing (4) up piston rod (1) and remove. Discard packing (4).

1. Coat packing (4) with GAA grease and position around piston rod (1).

2. Install packing (4) into cylinder head (5) and slide nut (3) onto cylinder head (5).

3. Using spanner wrench, tighten nut (3).4. Remove lifting device from wrecker boom (2).

5-610

5-103. BOOM

TM 9-2320-272-24-4

FOLLOW-ON TASK: Operate crane through full range (TM 9-2320-272-10) and check for leaks at cylinder.

5-611

5-104. DUMP

TM 9-2320-272-24-4

THIS TASK COVERS:a. Removal d. Assemblyb. Disassembly e. Installationc. Inspection and Repair

INITIAL SETUP:

APPLICABLE MODELSM929/A1/A2, M930/A1/A2

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Brass driftSoft-faced hammer

MATERIALS/PARTSGAA grease (Appendix C, Item 28)


EQUIPMENT CONDITION• Parking brake set (TM 9-2320-272-10).• Dump body removed (para. 4-144).

GENERAL SAFETY INSTRUCTIONSDo not operate dump controls when dump body isremoved.

WARNING

Ensure dump control lever is in neutral and not moved. Injury topersonnel may result if lift cylinder is operated when not secured.

NOTELeft and right roller arms are replaced basically the same way.This procedure covers right roller arm.

NOTEUse soft-faced hammer to tap roller arm if necessary to completestep 1.

Remove roller arm (3) from hoist cylinder crosshead shaft (1).

1. Using punch and hammer, remove two pins (2) from roller arm (3).2. Using brass drift and hammer, drive roller pin (5) out of roller arm (3) and roller (6).3. Remove roller (6) from roller arm (3).

1. Inspect roller (6) and roller pin (5). If cracked or deeply grooved, replace roller (6) and roller pin (5).

2. Inspect roller arm (3). If broken or cracked, replace.3. Inspect two bushings (4) in roller arm (3). If broken, cracked, or out-of-round, replace bushings (4).

NOTEPerform steps 4 and 5 only if bushings need to be replaced.

4. Using brass drift and hammer, drive two bushings (4) out of roller arm (3).5. Using wood block and hammer, drive one new bushing (4) in from each side of roller arm (3) until

bushings (4) are flush with roller arm (3).

5-612

5-104. DUMP

TM 9-2320-272-24-4

1. Position roller (6) in roller arm (3).2. Coat roller pin (5) with light film of GAA grease and insert through roller arm (3) and roller (6). Tap

pins (5) into place with soft-faced hammer.3. Install roller (6) on roller arm (3) with two pins (2)

Install roller arm (3) on hoist cylinder crosshead shaft (1).

FOLLOW-ON TASKS: Install dump body (para. 4-144).Lubricate roller arms (LO 9-2320-272-12).

5-613

5-105. DUMP

TM 9-2320-272-24-4

THIS TASK COVERS:a. Removal d. Assemblyb. Disassembly e . Ins ta l la t ionc. Cleaning and Inspection

INITIAL SETUP:

APPLICABLE MODELSM929/A1/A2, M930/A1/A2

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Spring tester (Appendix E, Item 131)Soft-faced hammerOutside micrometer (Appendix E, Item 80)Inside micrometer (Appendix E, Item 83)Torque wrench (Appendix E, Item 146)

MATERIALS/PARTSEight lockwashers (Appendix D, Item 393)Preformed packing (Appendix D, Item 511)O-ring (Appendix D, Item 466)Cotter pin (Appendix D, Item 75)Cap and plug set (Appendix C, Item 14)Lint-free cloth (Appendix C, Item 21)Clean hydraulic oil (Appendix C, Item 35)

WARNING

Ensure dump control is in neutral and not moved. Injury topersonnel may result if lift cylinder is operated when not secured.

REFERENCES (TM]LO 9-2320-272-12TM 9-2320-272-10TM 9-2320-272-24P

EQUIPMENT CONDITIONDump body removed (para. 4-144).Dump roller arms removed (para. 5-104).

GENERAL SAFETY INSTRUCTIONSDo not operate dump controls when dump body isremoved.

NOTEA 4x4 block of wood is recommended for use as support.

1. Raise hoist cylinders (3) and (9) from subframe (4) and place wood support between sub-frame (4) and cylinders (3) and (9).

2. Remove four screws (2), lockwashers (1), two upper crosshead retainers (5), lower crossheadretainers (7), and crosshead (8) from two piston rods (6). Discard lockwashers (1).

CAUTION

Plug all hydraulic lines or openings to prevent dirt from enteringand damaging components.

NOTECross fitting to hoist cylinder hoses must be disconnected fromcross fittings first. Then hoses can be removed from hoistcylinders.

Have drainage containers ready to catch oil.

Tag all parts for installation.

3. Disconnect hydraulic hoses (18) and (14) from right cross fitting (17).

5-614

5-105. DUMP

TM 9-2320-272-24-4

4. Disconnect hydraulic hoses (19) and (15) from left cross fitting (16).

5. Disconnect hydraulic hoses (18) and (14) from right and left cylinder ports A (10) and (12).6. Disconnect hydraulic hoses (19) and (15) from right and left cylinder ports B (11) and (13).

5-615

5-105. DUMP

TM 9-2320-272-24-4

7. Remove eight screws (3), lockwashers (4), four bearing caps (2), and hoist cylinders (5) and (1) fromsubframe (6). Discard lockwashers (4).

1.

Both hoist cylinders are disassembled the same way. Steps 1through 12 cover the left hoist cylinder.

Remove two square-head screws (18) from cylinder base (7) and slide hinge pin (19) out of cylinderbase (7).

2.

3.

4.

Remove three screws (11) from gland (12) and cylinder head (14).Tap gland (12) free of cylinder head (14) and slide off piston rod (16).

Remove ten screws (10) and lockwashers (9) from cylinder head (14) and hoist cylinder housing (8).Discard lockwashers (9).

5.

6.

Tap cylinder head (14) free of hoist cylinder housing (8) and slide cylinder head (14) off pistonrod (16).Remove packing (13) and O-ring (15) from cylinder head (14). Discard packing (13) and O-ring (15).

CAUTION

Use care when performing step 7 to prevent damage to cylinderbore or piston.

7. Pull piston rod (16) and piston (17) straight out of hoist cylinder housing (8).

NOTE

5-616

5-105. DUMP

TM 9-2320-272-24-4

5-617

5-105. DUMP

TM 9-2320-272-24-4

8. Remove cotter pin (12) and slotted nut (13) from piston rod (8) and piston (9). Discard cotter pin (12).9. Slide piston (9) off piston rod (8).

10. Remove three piston rings (11) from piston grooves (10).NOTE

Tag bypass plugs, springs, and check balls for installation.

11. Remove three bypass plugs (6), springs (5), and check balls (4) from hoist cylinder housing (7).12. Remove orifice plug cover (1) and orifice plug (2) from cylinder base (3).

NOTEUse clean lint-free cloth to wipe parts clean. After parts arecleaned and inspected, coat them with a light film of cleanhydraulic oil.

1. Wipe check balls (4) clean and inspect. Replace if scratched, chipped, or marked.2. Wipe piston (9) clean and inspect. Replace if cracked or broken.3. Measure outside diameter of piston (9). If outside diameter is less than 5.236 in. (132.994 mm),

replace piston (9).4. Wipe piston rod (8) clean and inspect. Replace if scratched, chipped, or scored.5. Measure outside diameter of piston rod (8). If outside diameter is less than 1.994 in. (50.648 mm),

replace piston rod (8).

5-618

5-105. DUMP

TM 9-2320-272-24-4

5-619

5-105. DUMP

TM 9-2320-272-24-4

6. Wipe head (5) and gland (6) clean and inspect. If cracked or broken, replace head (5) or gland (6).7. Measure inside diameter of head (5) and gland (6). If inside diameter is not 2.010 in. (51.05 mm),

replace head (5) or gland (6).8. Measure free length of three bypass springs (1). If length is not 1.25 in. (31.75 mm), replace bypass

spring (1).9. Compress each bypass spring (1) to 0.938 in. (23.8 mm) length. If torque reading is not 10 lb&

(14 N•m), replace bypass spring (1).10. Inspect three piston rings (11) for breaks. If any ring (11) is broken, replace all three rings (11).

11. Wipe orifice plug (2) and hoist cylinder walls (4) clean and inspect. If scratched or chipped, replaceorifice plug (2) or hoist cylinder walls (4).

NOTEBoth hoist cylinders are assembled in the same way. Steps 1through 12 cover the left hoist cylinder.

1. Install three piston rings (11) on piston grooves (10).2. Slide piston (9) on piston rod (8) until seated and install with slotted nut (13) and new cotter pin (12).

CAUTION

Use care when performing step 3 to prevent damage to cylinderbore or piston.

3. Slide piston (9) and piston rod (8) in cylinder housing (3).

4. Install new O-ring (7) on cylinder head (5).

5-620

5-105. DUMP

TM 9-2320-272-24-4

5-621

5-105. DUMP

TM 9-2320-272-24-4

5.6.

7.

8.

9.

10.

11.12.

Slide cylinder head (17) over piston rod (18) and position on cylinder housing (19).Install cylinder head (17) on cylinder housing (19) with ten new lockwashers (12) and screws (13).Tighten screws (13) 8-10 lb-ft (11-14 N-m).

Install packing (16) around piston rod (18) in cylinder head (17). Use fingers to position newpacking (16).

Slide gland (15) over piston rod (18) until seated against packing (16) and install on cylinder head (17)with three screws (14).Install orifice plug (2) and orifice plug cover (1) in cylinder base (3).

NOTEShort bypass tube connector block is located in middle of cylinder.

Install two bypass check balls (7), springs (6), and plugs (5) in short bypass tube connectorblock (4).

NOTELong bypass tube connector block is located at head end ofcylinder.

Install one bypass check ball (10), spring (9), and plug (8) in long bypass tube connector block (11).Position hinge pin (21) in cylinder base (3) until aligned with holes for screws (20) and install twosquare-head screws (20).

5-622

5-105. DUMP

TM 9-2320-272-24-4

1. Position hoist cylinders (27) and (22) on subframe (28) with bypass tubes (26) facing down.2. Install each hoist cylinder (27) and (22) with two bearing caps (23), four new lockwashers (25), and

screws (24).

NOTETo properly identify hose connection points, the cylinder port withbypass tube extending to the middle of the cylinder will beidentified as port B. The cylinder port with bypass tube extendingfull length of the cylinder will be identified as port A.

3. Connect hydraulic hoses (31) and (35) to left cylinder port A (38), right cylinder port A (29), andright cross fitting (34).

4. Connect hydraulic hoses (32) and (36) to left cylinder port B (30), right cylinder port B (37), and leftcross fitting (33).

5-623

5-105. DUMP

TM 9-2320-272-24-4

5. Position crosshead (2) on piston rods (1) and (3) and install with two upper crosshead retainers (7),lower crosshead retainers (8), four new lockwashers (4), and screws (5).

6. Raise hoist cylinders (6) and (9) and remove wood block.

5-624

5-105. DUMP

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install dump roller arms (para. 5-104).Install dump body (para. 4-144).Fill hydraulic reservoir to proper oil level (LO 9-2320-272-12).Start engine (TM 9-2320-272-10) and operate dump through full range. Check forleaks and proper operation.

5-625

5-106. BOOM

TM 9-2320-272-24-4

THIS TASK COVERS:

a. Disassembly c. Assemblyb. Cleaning, Inspection, and Repair

INITIAL SETUP:


SPECIAL TOOLSBushing installer (Appendix E, Item 23) EQUIPMENT CONDITIONHandle (Appendix E, Item 61) Extension cylinder removed (para. 4-196)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Spanner wrench (Appendix E, Item 166)

GENERAL SAFETY INSTRUCTIONSKeep fire extinguisher nearby when usingdrycleaning solvent.

MATERIALS/PARTSDrycleaning solvent is flammable and toxic. Donot use near an open flame.

Wiper strip (Appendix D, Item 720)Lockwire (Appendix D, Item 421)O-ring (Appendix D, Item 467)Packing (Appendix D, Item 510)Crocus cloth (Appendix C, Item 20)Drycleaning solvent (Appendix C, Item 71)Lint-free cloth (Appendix C, Item 21)

REFERENCES (TM)LO 9-2320-272-12TM 9-2320-272-24P

1. Using spanner wrench, remove cylinder head (21 from cylinder body (3).

2. Remove piston rod (11 from cylinder body (3).3. Remove lockwire (14) and piston rod nut (15) from piston rod (1). Discard lockwire (14).4. Remove washer (13), two U-cup retainers (9), U-cups (10), piston (11), cylinder head (2), and wiper

strip (5) from piston rod (1). Discard wiper strip (5).5. Remove packing nut (4), packing (6), O-ring (8), and piston rod bushing (7) from cylinder head (2).

Discard O-ring (8) and packing (6).

6. Remove two half rings (12) from piston (11).

5-626

5-106. BOOM

TM 9-2320-272-24-4

5-627

5-106. BOOM

TM 9-2320-272-24-4

WARNING


1. Clean all boom extension cylinder components with drycleaning solvent and dry with lint-free cloth(para. 2-14).

2. Inspect piston rod (6). Remove scratches and burrs with crocus cloth. Replace if scored or threadsare stripped.

3. Inspect piston (11) and cylinder body (1). Replace piston (11) or cylinder body (1) if scored.

1. Install two half rings (12) on piston (11).2. Using bushing installer and handle, install piston rod bushing (5) in cylinder head (7).3. Install new O-ring (8), new packing (4), packing nut (2), and new wiper strip (3) on cylinder head (7).

NOTEUse care not to damage wiper strip when passing over threads onpiston rod.

4. Install cylinder head (7) on piston rod (6).5. Install two U-cup retainers (9), U-cups (10), piston (11), and washer (13) on piston rod (6) with

piston rod nut (15) and new lockwire (14).6. Slide piston rod (6) into cylinder body (1) and install cylinder head (7) on cylinder body (1). Using

spanner wrench, tighten cylinder head (7).

5-628

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Lubricate extension cylinder (LO 9-2320-272-12).Install extension cylinder (para. 4-196).

5-629

6-107. CRANE

TM 9-2320-272-24-4

THIS TASK COVERS:a. Disassembly c. Assemblyb. Cleaning, Inspection, and Repair

INITIAL SETUP:

APPUCABLE MODELSM936/A1/A2

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Torque wrench (Appendix E, Item 144)Arbor pressMandrel

MATERIALS/PARTSTwo gearcase gaskets (Appendix D, Item 233)Gearcase seal (Appendix D, Item 6241Fifteen lockwashers (Appendix D, Item 350)Two woodruff keys (Appendix D, Item 734)Gasket (Appendix D, Item 234)Two woodruff keys (Appendix D, Item 736)Woodruff key (Appendix D, Item 735)Drycleaning solvent (Appendix C, Item 71)

REFERENCES (TM)LO 9-2320-272-12TM 9-2320-272-24P

EQUIPMENT CONDITIONCrane swinger gearcase removed (para. 4-200).

GENERAL SAFETY INSTRUCTIONSKeep fire extinguisher nearby when usingdrycleaning solvent.Drycleaning solvent is flammable and toxic. Donot use near an open flame.

1. Thoroughly clean exterior with drycleaning solvent (para. 2-14).NOTE

2.Have drainage container ready to catch oil.

Remove two drainplugs (8) from crane swinger gearcase (13) and drain lubricant from crane swingergearcase (13).

3.4.

5.

6.

7.

8.

Reinstall two drainplugs (8) in crane swinger gearcase (13).Remove four screws (11), lockwashers (12), shaft bearing cap (10), and gasket (9) from crane swingergearcase (13). Discard lockwashers (12) and gasket (9).

Remove four screws (5), lockwashers (4), gearcase motor mounting cap (6), and gasket (7) fromcrane swinger gearcase (13). Discard lockwashers (4) and gasket (7).

Remove six screws (l), lockwashers (14), cover (2), and gasket (3) from crane swinger gearcase (13).Discard lockwashers (14) and gasket (3).Using arbor press and mandrel, remove gear shaft assembly (20) from crane swinger gearcase (13).

Remove screw (15), lockwasher (25), and retaining washer (24) from gear shaft assembly (20).Discard lockwasher (25).

5-630

WARNING


TM 9-2320-272-24-4

NOTEUse puller to remove bearing and gear.

9. Remove upper bearing (23), thrust washer (22), gear (21), gear washer (16), lower bearing (17), seal (18),and two woodruff keys (19) from gear shaft assembly (20). Discard woodruff keys (19) and seal (18).

5-631

5-107. CRANE

TM 9-2320-272-24-4

10. Using arbor press and mandrel, remove coupling (11) and woodruff key (8) from shoulder shaft (10).Discard woodruff key (8).

11. Using arbor press and mandrel, press crane swinger gearcase (5) shoulder shaft (10) down untilbearing (1) is removed.

12. Turn crane swinger gearcase (5) over and press bearing (1) and shoulder shaft (10) assembly fromcrane swinger gearcase (5).

13. Remove two bushings (2), springs (3), spacers (4), washers (6), and woodruff keys (9) from shouldershaft (10). Discard woodruff keys (9).

14. Remove worm gear (7) from shoulder shaft (10).

WARNING


CAUTION

Do not spin-dry bearings with compressed air.1. Clean all crane swinger gearcase (5) components with drycleaning solvent.2. Inspect four bearings (1). Replace if scored, pitted, or broken.

3. Inspect crane swinger gearcase (5), gearcase motor mounting cap (14), shaft bearing cap (15), andgearcase cover (12) for cracks and breaks. Replace if cracked or broken.

4. Inspect shoulder shaft (10), worm gear (7), and gearshaft (13). Replace if broken, cracked, chipped,or out-of-round.

5-632

TM 9-2320-272-24-4

5-633

5-107. CRANE

TM 9-2320-272-24-4

1.

2.

3.

4.

5.6.7.

8.

9.

10.

11.

12.

13.

14.

Install two new woodruff keys (9), washers (6), spacers (4), springs (3), and bushings (2) on shouldershaft (10).Install worm gear (7) on shoulder shaft (10).

Using arbor press and mandrel, install shoulder shaft bearings (1) on shoulder shaft (10) and pressshoulder shaft (10) into crane swinger gearcase (5) until bearing (1) is flush with end of craneswinger gearcase (5).Turn crane swinger gearcase (5) over and, using arbor press and mandrel, press second shoulder shaftbearing (1) into crane swinger gearcase (5). Ensure bearing (1) is flush with crane swinger gearcase (5).Install new woodruff key (8) on shoulder shaft (10).Install new seal (14) on gear shaft (16).Using arbor press and mandrel, press bearing (13) onto gear shaft (16).Position lower thrust washer (12) and two new woodruff keys (15) on gear shaft (16) and, usingarbor press and mandrel, press gear (17) onto gear shaft (16) over woodruff keys (15).

Position upper thrust washer (18) on gear shaft (16) and, using arbor press and mandrel, pressbearing (19) onto gear shaft (16).Install retaining washer (20), new lockwasher (21), and screw (22) on gear shaft (16). Tightenscrew (22) 44-61 lb-ft (60-83 N•m).Install new gasket (23) and gearcase cover (24) on crane swinger gearcase (5) with six new lockwashers(25) and screws (11). Tighten screws (11) 44-61 lb-ft (60-83 N•m).

Install new gasket (28) and shaft bearing cap (27) on crane swinger gearcase (5) with four newlockwashers (26) and screws (34). Tighten screws (34) 44-61 lb-ft (60-83 N•m).Install coupling (29) in crane swinger gearcase (5).

Install new gasket (30) and mounting cap (31) on crane swinger gearcase (5) with four new lockwashers(32) and screws (33). Tighten screws (33) 44-61 lb-ft (60-83 N•m).

5-634

5-107. CRANE

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Fill crane swinger gearcase with lubricant (LO 9-2320-272-12).Install crane swinger gearcase (para. 4-200).

5-635

5-108. CRANE

TM 9-2320-272-24-4

THIS TASK COVERS:a. Disassembly c. Assemblyb. Cleaning, Inspection, and Repair

INITIAL SETUP:


SPECIAL TOOLSSeal retainer remover and replacer

(Appendix E, Item 117)

TOOLSGeneral mechanic’s tool kit (Appendix E, Item 1)Soft-jawed vise

MATERIALS/PARTSRelief valve kit (Appendix D, Item 533)


EQUIPMENT CONDITIONCrane control valve removed (para. 4-201).

GENERAL SAFETY INSTRUCT IONSKeep fire extinguisher nearby when usingdrycleaning solvent.Drycleaning solvent is flammable and toxic. Donot use near an open flame.

Load check valve kit (Appendix D, Item 270)Eight snaprings (Appendix D, Item 665)O-ring (Appendix D, Item 469)O-ring (Appendix D, Item 468)Four O-rings (Appendix D, Item 489)Four lockwashers (Appendix D, Item 350)Drycleaning solvent (Appendix C, Item 71)Lint-free cloth (Appendix C, Item 21)

NOTEDo not perform this procedure unless relief valve kit and loadcheck valve kit are available.

WARNING

Drycleaning solvent is flammable and toxic. Do not use near openflame and always have a fire extinguisher nearby when solvents areused. Use only in well-ventilated places, wear protective clothing, anddispose of cleaning rags in approved container. Failure to do this mayresult in injury or death to personnel and/or damage to equipment.

1. Thoroughly clean exterior of crane control valve (3) with drycleaning solvent (para. 2-14).2. Remove eight snaprings (21), pins (20), and four handles (19) from base (2) and crane control

valve (3). Discard snaprings (21).3. Remove four nuts (13), lockwashers (14), screws (1), control brackets (15) and (7), and base (2) from

crane control valve (3). Discard lockwashers (14).4. Remove nipple adapter (17) and O-ring (16) from crane control valve (3). Discard O-ring (16).5. Remove nipple (18) from nipple adapter (17).

NOTEMark position and angle of tube and all elbows for assembly.

6. Remove tube (6), connector (5), and O-ring (4) from crane control valve (3). Discard O-ring (4)7. Remove two elbows (10), three adapters (11), and two O-rings (12) from crane control valve (3).

Discard O-rings (12).8. Remove four elbows (9) and O-rings (8) from crane control valve (3). Discard O-rings (8).

5-636

5-108. CRANE

TM 9-2320-272-24-4

5-637

5-108. CRANE

TM 9-2320-272-24-4

NOTEAll spring-centered spool valves in the control valve are removedand disassembled the same way. Three spool valves are stampedwith a D (double action) on the shank of the spool valve. Thefourth is stamped with an S (single action) and is located next tothe oil outlet port in the control valve. Steps 9 through 12 willcover a double-action valve only.

9. Remove spool valve cap (3) and spool valve (2) from crane control valve (1).

10. Clamp spool valve (2) in soft-jawed vise.11. Using improvised compression tool, compress spring (6) and remove snapring (4), outer spacer (5),

spring (6), travel limit washer (7), and inner spacer (8) from spool valve (2).12. Using seal retainer remover and replacer, remove retainer (24), seal (25), and O-ring (26) from crane

control valve (1). Discard seal (25) and O-ring (26).

NOTEAll check valves in the control valve are removed and assembledthe same way. Check valves located adjacent to valve spoolsmarked with a D (double action) are identical. The check valvelocated by the valve spool marked S (single action) contains onlyone spring and poppet. All other components are the same asthe D-type spools. Steps 13 and 14 cover a check valve adjacentto a D-type spool.Do not remove check seat sleeve from control valve. Check valveparts should be identified so they may be returned to theiroriginal position during assembly.

13. Remove two check valve caps (9), springs (17), and poppets (14) from crane control valve (1).14. Remove backup ring (16), O-ring (15), backup ring (13), backup ring (12), O-ring (11), and

O-ring (10) from each check valve cap (9). Discard backup ring (16), O-ring (15), backup ring (13),backup ring (12), O-ring (11), and O-ring (10).

5-638

5-108. CRANE

TM 9-2320-272-24-4

15. Remove relief valve (23) from crane control valve (1). Discard relief valve (23).

16. Remove seat retainer plug (18), drain sleeve (20), and seat retainer (19) from crane controlvalve (1). Discard seat retainer (19).

17. Remove poppet spring (22) and poppet assembly (21) from crane control valve (1). Discard poppetassembly (21) and poppet spring (22).

5-639

5-108. CRANE

TM 9-2320-272-24-4

WARNING

Drycleaning solvent is flammable and toxic. Do not use near openflame and always have a tire extinguisher nearby when solventsare used. Use only in well-ventilated places, wear protectiveclothing, and dispose of cleaning rags in approved container.Failure to do this may result in injury or death to personnel and/ordamage to equipment.

1. Clean all control valve components with drycleaning solvent and dry with lint-free cloth (para. 2-14).2. Inspect spool valve (1) and crane control valve (2). Replace crane control valve (2) if grooved,

scratched, cracked, or broken.

1.2.3.

4.

5.

6.

7.

8.

9.10.

NOTEDrain sleeve should go into control valve far enough to leave twoor three full threads exposed. Installing seat retainer plug at thispoint sets the seat retainer to the proper depth.

Install new seat retainer (13) and drain sleeve (14) in crane control valve (2).Install seat retainer plug (12) in crane control valve (2).Install new poppet assembly (15) and poppet spring (16) in crane control valve (2) so poppetassembly (15) points toward seat retainer (13).

Install new relief valve (17) on crane control valve (2).

Install new O-rings (4) and (5), new backup rings (6) and (7), new O-ring (9), and new backup ring (10)on each check valve cap (3).Install two poppets (8), springs (ll), and check valve caps (3) into crane control valve (2).

NOTEThe remaining check valve caps are assembled the same way.

Clamp spool valve (1) in soft-jawed vise.

Using improvised compression tool, compress spring (21) and install inner spacer (23), travel limitwasher (22), spring (21), and outer spacer (20) on spool valve (1) with new snapring (19).

Install spool valve (1) and spool valve cap (18) in crane control valve (2).Using seal retainer remover and replacer, install new O-ring (26), new seal (25), and retainer (24)on crane control valve (2).

5-640

5-108. CRANE

TM 9-2320-272-24-4

5-641

5-108. CRANE

TM 9-2320-272-24-4

NOTEInstall all parts in steps 11 through 13 in their marked locationand angle on control valve.

The three remaining spool valves are assembled into the controlvalve in the same way.

11. Install four new O-rings (8), elbows (9), two new O-rings (12), three adapters (ll), two elbows (10),new O-ring (4), connector (5), and tube (6) on crane control valve (3).

12. Install nipple adapter (17) on nipple (18).

13. Install new O-ring (16) and nipple adapter (17) on crane control valve (3).

14. Install right control bracket (7), left control bracket (15),four screws (1), new lockwashers (14), and nuts (13).

and base (2) on crane control valve (3) with

15. Align four operating handles (19) with holes in base (2) and control spool valves (21), and installfour operating handles (19) with eight pins (20) and new snaprings (22).

5-642

TM 9-2320-272-24-4

5-108. CRANE CONTROL VALVE REPAIR (Contd)

FOLLOW-ON TASK: Install crane control valve (para. 4-201).

5-643/(5-644 blank)

TM 9-2320-272-24-4

CHAPTER 6SHIPMENT AND LIMITED STORAGE

Section I. General Preparation of Vehicle for Shipment (page 6-1)Section II. Loading and Movement (page 6-2)

Section III. Limited Storage (page 6-2)

Section I. GENERAL PREPARATION OF VEHICLE FOR SHIPMENT

6-1. SCOPE

a. This section provides instructions on preserving and protecting vehicles for shipment.b. Protection for vehicles and accompanying equipment must be sufficient to protect the material

against deterioration and physical damage.

6-2. CLEANING

W A R N I N G

Drycleaning solvent is flammable and will not be used near openflame. Use only in well-ventilated places. Failure to do so mayresult in injury to personnel.

Cleaning materials or paints containing chlorinated hydrocarbonclass solvents are not to be used on composite taillights andparking lights. Damage to taillight and parking light lenses mayresult.

Prior to application of preservatives, surfaces must be cleaned to ensure removal of corrosion, soil, grease,or vehicle acid and alkali residues.

a. Interior of Vehicle. Remove all dirt and other foreign matter from all painted metal surfaces ofvehicle by scrubbing with cloths soaked in drycleaning solvent (appendix C, item 71). DO NOT applysolvent to electrical equipment or rubber parts of any nature. Use trichloroethylene (appendix C, item 76) toclean electrical parts and electrical contact points. Use warm water for cleaning rubber parts. Applypreservative compounds to rubber parts as required (TM 9-247).

b. Exterior of Vehicle. Clean exterior surfaces of vehicle to ensure removal of all dirt and foreignmatter. After cleaning, immediately dry parts to remove excess cleaning solutions or residual moisture.Allow parts to air-dry or wipe with clean, dry, lint-free cloth (appendix C, item 21).

6-3. LUBRICATION

W A R N I N G

Drycleaning solvent is flammable and will not be used near openflame. Use only in well-ventilated places. Failure to do so mayresult in injury to personnel.

After cleaning has been accomplished, wipe all grease fittings clean with drycleaning solvent (appendix C,item 71) and lubricate vehicle in accordance with LO 9-2320-272-12. Remove excess grease after lubricationand before processing.

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TM 9-2320-272-24-4

6-4. PRESERVATION

All critical unpainted metal surfaces must be protected during shipment. Use procedures and materialslisted in steps a. and b. below. If the preservatives listed below are not available, oil or grease listed inLO 9-2320-272-12 may be used for this purpose, but is effective for only a few days; therefore, equipmentprotected must be closely watched for signs of corrosion. When selecting preservatives, use only those thatwill not damage the surface to which they are applied.

a. Battery Leads. Disconnect both batteries (para. 3-126). Each battery lead terminal, including thejumper lead ends, must be wrapped with tape (appendix C, item 73).

b. Miscellaneous Preservation. Coat all unpainted, exposed, or machined metal surfaces on theexterior of the vehicle with corrosion-preventive compound (appendix C, item 25).

6-5. PACKAGING

Electrical Openings. Cover all electrical receptacles with tape (appendix C, item 73) or with plastic capswhich will afford the same degree of protection.

6-6. PACKING

Pack all Basic Issue Items (BII) and Additional Authorization List (AAL) items to prevent mechanicaldamage.

6-7. SHIPMENT OF ARMY DOCUMENTS

Prepare all Army shipping documents accompanying vehicle in accordance with DA Pam 738-750.

Section II. LOADING AND MOVEMENT

6-8. LOADING AND MOVEMENT

For transportability guidance handling and movement of vehicles, refer to TM 55-2320-272-15-1.

Section III. LIMITED STORAGE

6-9. SCOPE

Commanders are responsible for ensuring that all vehicles issued or assigned to their command aremaintained in a serviceable condition and properly cared for and that personnel under their commandcomply with technical instructions. Lack of time, trained personnel, or proper tools may result in a unitbeing incapable of performing maintenance for which it is responsible. In such cases, unit commanders may,with the approval of major commanders, place a vehicle that is beyond the maintenance capability of theunit in administrative storage. For detailed maintenance information, refer to AB 750-1.

6-10. LIMITED STORAGE INSTRUCTIONS

a. Time Limitations. Administrative storage is restricted to a period of 90 days and must not beextended unless the vehicle is reprocessed in accordance with step b.

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TM 9-2320-272-24-4

6-10. LIMITED STORAGE INSTRUCTIONS (Contd)

b. Storage Procedure. Perform disassembly only as required to clean and preserve exposed surfaces.Except as otherwise noted, and to the maximum extent consistent with safe storage, place the vehicle inadministrative storage in as nearly a completely assembled condition as possible. Install and adjustequipment so that the vehicle may be placed in service and operated with minimum delay.

(1) The vehicle should be stored on level ground in the most favorable location available, preferablyone which affords protection from exposure to the elements and from pilferage.

(2) Perform semiannual Preventive Maintenance Checks and Services (PMCS) (para. 2-12) onvehicle intended for administrative storage. This maintenance consists of inspecting, cleaning, servicing,preserving, lubricating, adjusting, and replacing minor repair parts as required.

(3) Remove both batteries (para. 3-125), place in covered storage, and maintain a charged condition.(4) Provide access to the vehicle to permit inspection, servicing, and subsequent removal from

storage.

6-11. INSPECTION IN LIMITED STORAGE

a. Conduct visual inspection of vehicles in limited storage at least once a month and immediatelyfollowing hard rains, heavy snowstorms, windstorms, or other severe weather conditions. Performdisassembly as required to fully ascertain the extent of any discovered deterioration or damage. Maintain arecord of these inspections for each vehicle. Attach record to vehicle so it is protected from the weather,

b. Perform necessary reprocessing for limited storage when rust or deterioration is found on anyunpainted area. Immediately repair damage caused to vehicle by severe weather conditions. Repair damageto On-Equipment Materiel (OEM) as necessary. Thoroughly clean, dry, and repaint painted surfacesshowing evidence of wear.

6-12. REMOVAL FROM LIMITED STORAGE

Materiel removed from administrative storage will be:(1) Restored to normal operating conditions.(2) Repaired as required.(3) Returned to normal PMCS schedule using last type service completed as a starting point.(4) Calibrate equipment as required (TM 43-180).

6-3 (6-4 blank)

TM 9-2320-272-24-4

APPENDIX AREFERENCES

A-1. SCOPE

This appendix lists all forms, field manuals, and technical manuals for use with this manual.

A-2. PUBLICATIONS INDEX

The following indexes should be consulted frequently for latest changes or revisions and for new publicationsrelating to material covered in this manual.

Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Pam 25-30

Functional User’s Manual for The Army Maintenance Management System (TAMMS) . . . . DA Pam 738-750

A-3. FORMS

The following forms pertain to this manual. See DA Pam 25-30, Consolidated Index of Army Publicationsand Blank Forms, for index of blank forms. See DA Pam 738-750, The Army Maintenance ManagementSystem (TAMMS), for instructions on the use of maintenance forms pertaining to this manual.

Unit Status Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 220-1

U.S. Army Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 285

Equipment Operator’s Qualification Record (Except Aircraft). . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 348

Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028

Recommended Changes to Equipment Technical Publications . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2

Organizational Control Record for Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2401

Exchange Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2402

Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404

Maintenance Request Register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2405

Materiel Condition Status Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2406

Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407

Maintenance Request - Continuation Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407-1

Equipment Log Assembly (Records) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408

Equipment Control Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9

Equipment Maintenance Log (Consolidated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2409

Packaging and Improvement Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 6

Preventive Maintenance Schedule and Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 314

Accident Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518

Processing and Deprocessing Record for Shipment, Storage, andIssue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397

U.S. Government Motor Vehicle Operator’s Identity Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OF Form 346

Operator Report on Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 91

Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 364

Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368

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TM 9-2320-272-24-4

A-4. FIELD MANUALS

NBC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-4NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-5Camouflage.. FM 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation and Maintenance of Army Materiel in Extreme Cold Weather (0°F to -65°F). . . . . . . . . . FM 9-207General Fabric Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-16Petroleum Supply Point Equipment and Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-69First Aid for Soldiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11Manual for the Wheeled Vehicle Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70Northern Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71Metal Body Repair and Related Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 43-2

A-5. TECHNICAL MANUALS

Chemical, Biological, and Radiological (CBR) Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-220Operator’s and Unit Maintenance Manual (Including Repair Parts and Special Tool List)

for Decontaminating Apparatus, Portable, DST, 1 1/2 Quart, ABC-M11) . . . . . . . . . . TM 3-4230-204-12&POperator’s and Organizational Maintenance Manual:

For Alarm, Chemical Agent, Automatic: Portable, Manpack, M8. . . . . . . . . . . . . . . . . . . TM 3-6665-225-12Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-725Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214Operator’s Manual for Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237Deep-Water Fording of Ordnance Materiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-238Use and Care of Hand Tools and Measuring Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-243Materials Used for Cleaning, Preserving, Abrading and Cementing Ordnance Materiel,

and Related Materials Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247

Operator, Organizational, Direct Support and General Support Maintenance ManualIncluding Repair Parts and Special Tool Lists (Including DepotMaintenance Repair Parts and Special Tools) Various Machine Gun Mountsand Combinations Used on Tactical and Armored Vehicles Mounts. . . . . . . . . . . . . . . . . TM 9-1005-245-14

Operator’s Manual for Truck, 5-Ton, 6x6, M939 and M939A1 Series (Diesel), Truck,Cargo: 5-Ton, 6x6, Dropside, M923, M923A1, M925, M925A1. . . . . . . . . . . . . . . . . . . . . TM 9-2320-272-10

Unit, Direct, and General Support Maintenance Rear Parts, Special Tools List forTruck, 5-Ton, 6x6, M939 and M939A1 Series (Diesel),Truck, Cargo, 5-Ton, 6x6, Dropside, M923, M923A1, M925, and M925A1. . . . . . . . . . . TM 9-2320-272-24P

Operator’s, Unit, Direct Support, and General Support Maintenance Manual forCare, Maintenance, Repair, and Inspection of Pneumatic Tires and Inner Tubes . . . . . TM 9-2610-200-14

Maintenance, Direct and General Support Level Generator Assembly(Prestolite Model AMA-5102UT) (Leece-Neville Models) . . . . . . . . . . . . . . . . .

Direct Support, General Support, and Depot Maintenance Manual(Including Repair Parts) for Starter, Engine, Electrical, Assembly(Delco-Remy Model 1113943) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direct Support and General Support Maintenance Manual(Including Repair Parts and Special Tools List) for Starter, Engine, Electrical(Leece-Neville Model M001707 2MB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . TM 9-2920-225-34

. . . . . . TM 9-2920-242-35

. . . . . . TM 9-2920-243-34

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TM 9-2320-272-24-4

A-5. TECHNICAL MANUALS (Contd)

Operator’s Manual for Lathe, Brake Drum, Floor Mounted, 60-Inch Rated Swing;25 Inch Maximum Drum Diameter, 115 Volt, 60 Cycle, Single Phase . . . . . . . . . . . . . . . TM 9-4910-482-10

Operator’s Manual: Grinding Machine, Valve Face, Bench Mounting,9/32 Inch to 11/16 Inch Chuck, 0 to 45 Degree Valve Face Angle Adjustment, 115-Volt,AC/DC, 60-Cycle, Single Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-4910-484-10

Operator’s and Organizational Maintenance Manual Including Repair Parts andSpecial Tools List for Simplified Test Equipment for Internal Combustion Engines. . . TM 9-4910-571-12&P

Operator’s, Unit, Intermediate Direct Support, and Intermediate General SupportMaintenance Manual for Lead-Acid Storage Batteries; 4HN, 24-Volt; 2HN, 12-Volt. . . . TM 9-6140-200-14

Principles of Automotive Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-8000Packaging of Materiel: Preservation Vol. I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-1Packaging of Materiel: Packing Vol. II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-2Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139Transportability Guidance (Trucks, 5-Ton, 6x6, M809 series)

Truck, Cargo, WWN, M813; Truck Cargo, Dropside, WWN, M813A1. . . . . . . . . . . . . TM 55-2320-260-15-1Administrative Storage of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 740-90-1Storage and Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 743-200-1General Packing Instructions for Field Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 746-10Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use

(U.S. Army Tank-Automotive Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-6Cooling Systems: Tactical Vehicles (Reprinted W/Basic Including Cl and C2) . . . . . . . . . . . . . . . TM 750-254

A-6. TECHNICAL BULLETINS

Load-Testing Vehicles Used to Handle Missiles and Rockets: Medium Wrecker: M62;Medium Wrecker, Truck: M543 Series and M816 and Wrecker, Truck Tractor,M246 Series and M819 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-352

Tactical Wheeled Vehicles: Repair of Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-247-40Standards for Oversea Shipment or Domestic Issue of Special Purpose Vehicles,

Combat, Tactical, Construction, and Selected Industrial and Troop Support,US Army Tank-Automotive Materiel Readiness Command . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-281-35

Truck, 5-Ton, 6x6 M939 Series Truck, Warranty Procedures for Cummins Engine,Model NHC 250 (NSN 2815-01-111-2262) and Allison TransmissionModel MT654CR (2520-01-117-30101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-295-15/21

Warranty Program for Truck, 5-Ton, 6x6 M939A2 Series Truck, Cargo:5-Ton, 6x6, Dropside, M923A2, M925A2 Truck, Cargo: 5-Ton, 6x6, XLWB, M927A2 . . . . TB 9-2300-358-24

Mandatory Brake Hose Inspection and Replacement-Tactical Vehicles. . . . . . . . . . . . . . . . TB 9-2300-405-14Security of Tactical Wheeled Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-422-20Calibration and Repair Requirements for the Maintenance of Army Materiel. . . . . . . . . . . . . . . . . TB 43-180Equipment Improvement Report and Maintenance Digest

(US Army Tank-Automotive Command) Tank and Automotive Equipment . . . . . . . . . . . . TB 43-0001-39-1Safety, Inspection, and Testing of Lifting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0142Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment,

and Materials Handling Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209Non-Aeronautical Equipment, Army Oil Analysis Program (AOAP) . . . . . . . . . . . . . . . . . . . . . . . TB 43-0210

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TM 9-2320-272-24-4

A-6. TECHNICAL BULLETINS (Contd)

Purging, Cleaning, and Coating Interior Ferrous and Term Sheet Vehicle Fuel Tanks . . . . . . . . TB 43-0212Corrosion Prevention and Control Including Rustproofing Procedures for

Tactical Vehicles and Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0213Functional Grouping Codes; Combat, Tactical, and Support Vehicles and

Special Purpose Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-93-1Maintenance Expenditure Limits for FSC Group 23, FSC Classes 2310, 2320, 2340,

a n d 2 3 5 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-98-23Use of Antifreeze Solutions, Antifreeze Extender, Cleaning Compounds, and

Test Kit in Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651Occupational and Environmental Health: Hearing Conservation . . . . . . . . . . . . . . . . . . . . . . TB MED 501Description, Use, Bonding Techniques, and Properties of Adhesives . . . . . . . . . . . . . . . . . . . . TB ORD 1032Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB SIG 222

A-7. OTHER PUBLICATIONS

Preventive Medicine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 40-5

Army Acquisition Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-1

Identification and Distribution of DA Publications and Issue of Agency andCommand Administrative Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-2

Dictionary of United States Army Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-25

Authorized Abbreviations and Brevity Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-50

Accident Reporting and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-40

Prevention of Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-55

The Army Driver and Operator Standardization Program (Selection, Training, Testing, andLicensing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 600-55

Packing of Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 700-15Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100

Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) . . . . . . . CTA 50-970

Methods of Preservation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-P-116

Marking for Shipment and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-129

Magnetic Particles Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-1949

Inspection, Liquid Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-6866

Vehicles, Wheeled, Preparation for Shipment and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-V-62038

Softwood Lumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MM-L-751

Winterization Kits for Army Tank-Automotive Materiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 9-16

A-4

TM 9-2320-272-24-4

APPENDIX BMAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION

a. This section provides a general explanation of all maintenance and repair functions authorized atvarious maintenance categories.

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibilityfor the performance of maintenance functions on the identified end item or component. The application ofthe maintenance functions to the end item or component will be consistent with the capacities andcapabilities of the designated maintenance categories.

c. Section III lists the tools and test equipment (both special tools and common tool sets) required foreach maintenance function as referenced from section II.

d. Section IV contains supplemental instructions and explanatory notes for a particular maintenancefunction.

B-2. MAINTENANCE FUNCTIONS

Maintenance functions will be limited to and defined as follows:a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or

electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical

characteristics of an item and comparing those characteristics with prescribed standards.c. Service. Operations required periodically to keep an item in proper operating condition; i.e., to clean

(includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants,chemical fluids, or gasses.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position,or by setting the operating characteristics to specified parameters.

e. Align. To adjust specified variable elements of an item to bring about optimum or desiredperformance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test,measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of twoinstruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy inthe accuracy of the instrument being compared.

g. Remove/Install. To remove and install the same item when required to perform service or othermaintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repairpart, or module (component or assembly) in a manner to allow the proper functioning of an equipment orsystem.

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.“Replace” is authorized by the MAC and is shown as the 3d position code of the SMR code.

i. Repair. The application of maintenance services, including fault location/troubleshooting,removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troublesand restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part,subassembly, modules (component or assembly), end item, or system.

B-l

TM 9-2320-272-24-4

B-2. MAINTENANCE FUNCTIONS (Contd)

j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completelyserviceable/operational condition as required by maintenance standards in appropriate technicalpublications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhauldoes not normally return an item to like-new condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipmentto a like-new condition in accordance with original manufacturing standards. Rebuild is the highest degreeof materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning tozero those age measurement (hours/miles, etc.) considered in classifying Army equipment/components.

B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II

a. Column (1) - Group Number. Column 1 lists functional group code numbers, the purpose of whichis to identity maintenance significant components, assemblies, subassemblies, and modules with the nexthigher assembly. End item group number shall be “00.”

b. Column (2) - Component/Assembly. Column 2 contains the names of components, assemblies,subassemblies, and modules for which maintenance is authorized.

NOTEThose components that are unique to M939A2 series vehicles areidentified in column 2 by an asterisk (*).

c. Column (3) - Maintenance Function. Column 3 lists the functions to be performed on the itemlisted in column 2. (For detailed explanation of these functions, see para. B-2.)

d. Column (4) - Maintenance Category. Column 4 specifies, by the listing of a work-time figure inthe appropriate subcolumn(s), the category of maintenance authorized to perform the function listed incolumn 3. This figure represents the active time required to perform that maintenance function at theindicated category of maintenance. If the number or complexity of the tasks within the listed maintenancefunction varies at different maintenance categories, appropriate work-time figures will be shown for eachcategory. The work-time figure represents the average time required to restore an item (assembly,subassembly, component, module, end item, or system) to a serviceable condition under typical fieldoperating conditions. This time includes preparation time (including any necessary disassembly/assemblytime), troubleshooting/fault location time, and quality assurance/quality control time in addition to the timerequired to perform the specific tasks identified for the maintenance functions authorized in the MAC. Thesymbol designations for the various maintenance categories are as follows:

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator or Crew0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit MaintenanceF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Support MaintenanceH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Support Maintenance

e. Column (5) - Tools and Equipment. Column 5 specifies, by code, those common tool sets (notindividual tools) and special tools, TMDE, and support equipment required to perform the designatedfunction.

f. Column (6) - Remarks. This column shall, when applicable, contain a letter code, in alphabeticorder, which shall be keyed to the remarks contained in section IV

B-2

TM 9-2320-272-24-4

B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS,SECTION III

a. Column (1) - Reference Code. The tool and test equipment reference code correlates with a codeused in the MAC, section II, column 5.

b. Column (2) - Maintenance Category. The lowest category of maintenance authorized to use thetool or test equipment.

c. Column (3) - Nomenclature. Name or identification of the tool or test equipment.

d. Column (4) - National/NATO Stock Number. The National Stock Number (NSN) of the tool ortest equipment.

e. Column (5) - Tool Number. The manufacturer’s part number.

B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV

a. Column (1) - Reference Code. The code recorded in column 6, section II.b. Column (2) - Remarks. This column lists information pertinent to the maintenance function being

performed as indicated in the MAC, section II.

B-3

TM 9-2320-272-24-4

Section II. MAINTENANCE ALLOCATION CHART

(2) (3) (4)Maintenance Category (5) (6)

Number

010100

component/Assembly

ENGINEEngine Assembly

MaintenanceFunction

Unit Tools andF H Equipment Remarks

InspectTestServiceReplaceRepair

0.11.52.0

0.11.52.0

0.2

0.2

2 thru 52 thru 57 thru 97, 11 thru13

A

A

B

A

V

0101

0.32.0

0102 Crankshaft

0.2

0.5

0103

Engine Assembly*

Mount, Engine Lifting

Bracket, Engine Mounting

Head, Cylinder Assembly

Sleeve, Cylinder

Liner, Cylinder*

Damper, Vibration

Flange, Crankshaft

Flywheel, Ring Gear

Housing, Flywheel Gear

Ring Gear, Flexplate*

8.016.0

Overhaul

InspectTestServiceReplaceRepairOverhaulInspectReplaceInspectReplaceInspectReplaceRepairInspectReplace

40.0

8.014.040.0

0.2

2.0

0.24.0

5.00.32.0

InspectReplace

InspectReplace

1.55.0

Repair 6.0

InspectReplace

InspectAdjustReplaceInspectReplaceInspectReplaceInspectReplacethru 9,23

1.0

0.20.50.41.01.0

4.01.01.0

2 thru 52 thru 57 thru 912, 13,34 thru 37

6 thru 9

6 thru 9

6 thru 96 thru 9

7, 11 thru13

7, 11, 1323,34 thru36

7, 11 thru137, 11 thru13

6 thru 9

6 thru 96 thru 9

6 thru 9

6 thru 9

6

*(M939A2 only)B - 4

TM 9-2320-272-24-4

Section II. MAINTENANCE ALLOCATION CHART (Contd)

(1) (2) (3)(4)

Maintenance Category(5) (6)

Group Maintenance Unit Tools andNumber Component/Assembly Function C O F H Equipment Remarks

ENGINE (Contd)

0103 Housing, Flywheel* Inspect 0.5(Contd) Replace 4.0 6 thru 9,

23Cover, Rear* Inspect 0.1 0.2

Replace 1.0 6 thru 9,23

Seal, Rear Oil* Inspect 0.1 AReplace 6.0 6 thru 9,

230104 Piston Assembly Inspect 0.3

Replace 5.0 9 thru 11Repair 2.0 9 thru 11

Piston Assembly* Inspect 0.3Replace 5.0 9 thru 11,

23Repair 2.0 9 thru 11

Rod, Connecting Inspect 0.3Replace 2.0 7, 11 thru

130105 Valve Cover Inspect 0.1 A

Replace 1.0 9 thru 11

Valve Cover* Inspect 0.1 AReplace 1.0 2 thru 5

Assembly, Rocker Lever* Inspect 0.5Adjust 0.5 6 thru 9Replace 1.5 6 thru 9

Rod, Push, Intake/Exhaust* Inspect 0.1Replace 0.5 6 thru 9

Shaft, Rocker Lever* Inspect 0.3Replace 2.0 6 thru 9

Tube, Oil Manifold* Inspect 0.1Replace 2.0 6 thru 9

Spring, Valve Inspect 0.3Replace 0.5 6 thru 9

Valves, Intake and Exhaust Inspect 0.2Replace 1.5 7, 11 thru

13Repair 0.5 9 thru 13

Cover, Front Gear Inspect 0.2Replace 2.0 6 thru 9

Seal, Front Oil Inspect AReplace 2.0 6 thru 9

* (M939A2 only)B-5

TM 9-2320-272-24-4


(1) (2) (3)(4)


Maintenance U n i t Tools andNumber Component/Assembly Function C O F H Equipment Remarks

ENGINE (Contd)0105 Housing, Front Gear* Inspect 0.1 0.2 A

(Contd) Replace 4.0 6 thru 9Shaft Assembly, Rocker Arm Inspect 0.3

Replace 2.0 6 thru 9Bearing, Camshaft Inspect 0.5

Replace 2.0 7, 11 thru13

Camshaft Inspect 0.2Replace 1.0 7, 11 thru

13Camshaft, Gear Inspect 0.2

Replace 2.0 7, 11 thru13

Camshaft* Inspect 0.5Replace 1.5 7, 11 thru

13, 20Camshaft, Gear* Inspect 0.2

Replace 2.0 7, 11 thru13, 20

Bushings, Camshaft* Inspect 0.2Replace 6.5 7, 11 thru

13, 20Tappets* Inspect 0.1

Replace 4.0 7, 11 thru13, 20

0106 Crankcase Breather Inspect 0.5Replace 1.0 2 thru 5

Pump, Oil* Inspect 0.5Replace 4.0 2 thru 5

Oil (Dipstick) Tube Inspect 0.2 AReplace 0.3 2 thru 5

Cooler, Engine Oil* Replace 1.0Repair 1.5 2 thru 5

Head, Filter* Inspect 0.1Replace 0.5 2 thru 5

Oil Pan* Inspect 0.1 AReplace 4.2 6 thru 9

Tube, Oil Suction* Inspect 0.1Replace 0.5 6 thru 9

Pump, Oil Inspect 0.5Replace 2.0 6 thru 9Repair 4.0 7, 10 thru

13

* (M939A2 only)B-6

TM 9-2320-272-24-4


(1) 12) (3)(4)


Maintenance Unit Tools and

Number Component/Assembly Function C O F H Equipment Remarks

ENGINE (Contd)0106 Oil Pan Inspect 0.2

(Contd) Replace 1.0 6 thru 9

Oil Filter Inspect 0.1Replace 0.5 2 thru 5

Oil Cooler, Engine Inspect 0.5Replace 0.7 6 thru 9Repair 1.0 6 thru 9

0108 Manifold, Intake Inspect 0.5Replace 3.0 6 thru 9

Manifold, Exhaust Inspect 0.5Replace 2.0 6 thru 9

03 FUEL SYSTEM0301 Injectors, Fuel Inspect 0.5

Test 0.5 7, 11 thru13

Adjust 0.5 7, 11 thru13

Replace 1.5 6 thru 9Repair 1.0 7, 11 thru

13Calibrate 2.0 7, 11 thru

13Overhaul 1.0 7, 11 thru

13

Injectors, Fuel* InspectTest

ReplaceRepair

0.51.5 7, 11 thru

13, 22, 382.0 6 thru 9

1.0 7, 11 thru13, 22, 25

0302 Pump, Fuel Supply Inspect 0.5Replace 2.0 6 thru 9Adjust 2.0 7, 11 thru

13Repair 4.0 7, 11 thru

13Calibrate 2.0 7, 11 thru

13Overhaul 4.0 7, 11 thru

13

Lines and Fittings, Injection Inspect 0.1 APump* Replace 0.5 2 thru 5 D

Tubes, Fuel Injector* Inspect 0.1Replace 1.0 2 thru 5

* (M939A2 only)B-7

TM 9-2320-272-24-4

Section II. MAINTENANCE ALLOCATION CHART (Contd)(1) (2) (3) (4)

Maintenance Category (5) (6)

Maintenance Unit Tools andNumber Component/Assembly Function C O F H Equipment Remarks

FUEL SYSTEM (Contd)0302 Fuel Injection Pump* Inspect 0.5

(Contd) Test 5.0 7, 11 thru13, 33

Adjust 1.0 7, 11 thru13, 33

Calibrate 6.0 7, 11 thru U13, 33

Replace 2.0 2 thru 5,23, 39

Repair 4.0 7, 11 thru13, 27 thru32

Fuel Transfer Pump* Inspect 0.2Replace 0.3 2 thru 5

0304 Cleaner, Air Inspect 0.2 AReplace 0.5 2 thru 5

Element Service 0.5 AReplace 0.5

Lines and Connections, Vent Inspect 0.5Replace 1.0 2 thru 5 D

Indicator, Air Cleaner Inspect 0.2 ATest 0.2Replace 0.5 2 thru 5

Hoses and Clamps Inspect 0.1 AReplace 0.5 2 thru 5

0305 Hoses and Clamps, Inspect 0.2 ATurbocharger* Replace 1.0 2 thru 5Tube, Oil Drain* Inspect 0.2 A

Replace 1.0 2 thru 5Turbocharger Assembly* Inspect 0.6


0306 Tank, Fuel Inspect 0.1 AReplace 1.0 2 thru 5Repair 1.0 6 thru 9 C

Bracket, Fuel Tank Inspect 0.1 AMounting Replace 1.0 2 thru 5Lines and Fittings, Fuel Inspect 0.1 A

Replace 1.5 2 thru 5 DValve, Fuel Selector Inspect 0.1 A

Replace 1.0 2 thru 5Lines and Fittings, Fuel Inspect 0.1 APump to Engine Replace 1.0 2 thru 5 D

*(M939A2 only)B-8

TM 9-2320-272-24-4


Number

0308 0.51.2

2.5

0.51.0

2.0

0.51.0

2.0

0.51.0

2.0

0.51.0

2.0

0.20.1

0 . 5

0309

0311

0.10.5

0.10.5

0.51.0

0.11.0

0.10.21.0

0.20.51.0

0312

(2)

Component/Assembly

FUEL SYSTEM (Cod)Governor, Fuel Pump (AFC)

Spring Pack, Fuel Pump

Governor, Fuel Pump (VS)

Lower Spring Pack,Fuel Pump

Upper Spring Pack,Fuel Pump

Governor, Fuel InjectionPump*

Fuel Filter

Filter, Fuel Water Separator

Aids, Engine StartingLines and FittingsPump, Hand Primer

Harness and Switch

Control, Accelerator andThrottle Linkage

(3)(4)


MaintenanceFunction F

Tools andEquipment Remarks

InspectTest

Replace

InspectTest

Replace

InspectTest

Replace

InspectTest

Replace

InspectTest

Replace

InspectReplace

Repair

ServiceReplace

ServiceReplaceInspectReplaceInspectReplace

InspectTestReplace

InspectAdjustReplace

7, 11 thru137, 11 thru13

7, 11 thru137, 11 thru13

7, 11 thru137, 11 thru13

7, 11 thru137, 11 thru13

7, 11 thru137, 11 thru13

7, 11 thru137, 11 thru13

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 52 thru 15

2 thru 52 thru 5

A

A

D

* (M939A2 only)B-9

TM 9-2320-272-24-4


Number

040401

050501

0502

0503

0504

0505

(3)

Maintenance UnitComponent/Assembly Function c O

EXHAUST SYSTEM

Pipe, Exhaust and Tail Inspect 0.2Replace 2.0 2 thru 5

Muffler Inspect 0.2Replace 2.0 2 thru 5

Shield, Vertical Exhaust Inspect 0.1Replace 1.0 2 thru 5

COOLING SYSTEMRadiator Inspect 0.2 0.2

Service 0.3Replace 2.0 2 thru 5Repair 3.0 6 thru 9

Tank, Surge Inspect 0.2Service 0.1 0 2Replace 1.0 2 thru 5

Radiator Hoses Inspect 0.2Replace 0.5 2 thru 5

Canister, Thermostat* Inspect 0.1Replace 0.5

Shroud, Radiator Fan Inspect 0.1Replace 1.0 2 thru 5

Water Manifold and Headers Inspect 0.5Replace 1.0 6 thru 9

Coolant Lines, Air Inspect 0.5Compressor Replace 1.0 6 thru 9Actuator, Fan Clutch Inspect 0.2

Replace 0.4 2 thru 9Thermostats and Housing Inspect 0.1 0.2

Replace 1.0 2 thru 5Pump, Water* Inspect 0.1

Replace 1.5 2 thru 5Pump, Water Inspect 0.5


Belt, Water Pump Inspect 0.1 0.1Adjust 0.3 2 thru 5Replace 0.5 2 thru 5

Fan Assembly Inspect 0.1 0.1Replace 1.0 2 thru 5

Clutch, Fan Drive Inspect 0.2Replace 0.5 2 thru 5Repair 1.0 6 thru 9

Pulley, Belt Tensioner* Inspect 0.1Replace 0.5 2 thru 5

(4)Maintenance Category (5) (6)

Tools andEquipment Remarks

A

E

A

A

A

A

A

A

A

*(M939A2 only)B-10

TM 9-2320-272-24-4


(1) (2) (3) (4)Maintenance Category (5) (6)

Group Maintenance Unit Tools andNumber Component/Assembly Function C O F H Equipment Remarks

COOLING SYSTEM (Contd)0505 Drivebelt, Fan Inspect 0.1 A

(Contd) Replace 0.3 2 thru 5Fan Actuator* Inspect 0.1 A

Replace 0.8 2 thru 50507 Aftercooler, Engine* Inspect 0.3

Replace 1.0 2 thru 506 ELECTRICAL SYSTEM

0601 Alternator Inspect 0.1Adjust 0.6 6 thru 9Test 0.5 2 thru 5Replace 1.0 2 thru 5Repair 1.0 6 thru 9

Belt, Alternator Inspect 0.1 AAdjust 0.2 2 thru 5Replace 0.3 2 thru 5

0603 Starter Inspect 0.1Test 0.5 2 thru 5Replace 1.5 2 thru 5Repair 1.0 6 thru 9 G

0606 Valve, Fuel Shutoff Electrical Inspect 1.0Replace 0.7 6 thru 9

0607 Switches and Circuit Inspect 0.2 ABreakers Test 0.7 2 thru 5

Replace 1.0 2 thru 5Instruments and Gauges Inspect 0.1 A

Test 0.2 2 thru 5Replace 1.0 2 thru 5

0608 Control, Directional Turn Inspect 0.1 AIndicator Test 0.2 2 thru 5


Flasher Inspect 0.1 AReplace 0.5 2 thru 5

Box, Protective Control Test 0.3 2 thru 5Replace 0.7 2 thru 5

0609 Lights Inspect 0.1 2 thru 5 AAdjust 0.2 2 thru 5Replace 0.5 2 thru 5

0610 Unit, Sending Inspect 0.1Replace 0.3 2 thru 5

Switch, Stoplight Inspect 0.1Replace 0.5 2 thru 5

Buzzer, Warning Control Inspect 0.1 AReplace 0.3 2 thru 5

* (M939A2 only)B-11

TM 9-2320-272-24-4

Sect ion II . MAINTENANCE ALLOCATION CHART (Contd)


Maintenance Unit Tools andNumber Component/Assembly Function C O F H Equipment Remarks

ELECTRICAL SYSTEM (Contd)0610 Transponder, Fuel Pump Inspect 0.2


0611 Horn Inspect 0.1 AReplace 0.5 2 thru 5

Switch, Horn Inspect 0.1Replace 0.5 2 thru 5

0612 Battery Inspect 0.1 ATest 0.5 2 thru 5Service 0.5 AReplace 0.5 2 thru 5Repair 1.0 2 thru 5 H

Cables, Battery Inspect 0.1 AReplace 0.8 2 thru 5Repair 0.5 2 thru 5

Box, Battery Inspect 0.1 AReplace 1.8 2 thru 5Repair 1.5 2 thru 5

0613 Harness, Chassis Wiring Inspect 0.1 ATest 0.5 2 thru 5Replace 4.5 6 thru 9Repair 1.0 2 thru 5

07 TRANSMISSION

0705 Modulator Control Cable Adjust 0.5 2 thru 5Replace 0.7 2 thru 5

0708 Torque Converter/Flywheel Replace 8.0 6 thru 9Assembly Repair 5.0 7, 11 thru

14

0710 Transmission Assembly Inspect 0.2 ATest 1.0 6 thru 9Service 0.5 1.0 2 thru 5Adjust 2.5 6 thru 9Replace 6.0 6 thru 9Repair 8.0 10.0 6 thru 9,

11 thru 14Overhaul 20.0 I

Linkage, Shift Cable Inspect 0.1Adjust 1.0 6 thru 9Replace 1.0 6 thru 9

0721 Transmission Oil Cooler Inspect 0.1 AReplace 2.0 6 thru 9

Lines and Fittings Inspect 0.2 AReplace 1.0 6 thru 9 D

Transmission Oil Cooler* Inspect 0.2Replace 1.5 2 thru 5

* (M939A2 only)

B-12

TM 9-2320-272-24-4



Maintenance Unit GeneralSupport Tools and

Number Component/Assembly Funct ion C O F H Equipment Remarks

TRANSMISSION (Contd)0721 Lines and Fittings* Inspect 0.1 A

(Contd) Replace 1.0 2 thru 508 TRANSFER CASE ASSEMBLY0801 Transfer Case Assembly Inspect 0.3

Service 0.5 2 thru 5 AReplace 5.0 6 thru 9Repair 3.0 4.0 6 thru 14Overhaul 9.5 J

Coupling, Yoke Input and Inspect 0.3output Replace 1.0 6 thru 9Flange, Output Inspect 0.3

Replace 1.0 6 thru 9Cushion, Mounting Inspect 0.2

Replace 1.0 6 thru 9Gear, Speedometer Inspect 0.2

Replace 0.5 6 thru 9Seals, Input and Output Inspect 0.5Shaft Replace 2.0 6 thru 9Bearings, Gears, and Inspect 0.5Shafts Replace 2.0 7, 11 thru

14Repair 3.0 7, 11 thru

140803 Controls and Linkage Inspect 0.5

Adjust 0.3 6 thru 9Replace 1.5 6 thru 9Repair 1.0 6 thru 9

Cylinder, Air Shift Inspect 0.5Replace 2.0 6 thru 9Repair 0.7 6 thru 9

09 PROPELLER SHAFTS0900 Shaft Assembly, Propeller Inspect 0.3

Service 0.5 2 thru 5 AReplace 1.5 2 thru 5Repair 1.0

Joint, Universal Inspect 0.2 AService 0.3 2 thru 5Replace 1.5 2 thru 5

Dampener, Vibration Service 0.1Replace 0.7 2 thru 5

Bearing, Center Inspect 0.2Replace 1.5 2 thru 5

* (M939A2 only)B-13

TM 9-2320-272-24-4



Maintenance Unit General

Number Component/ AssemblySupport Tools and

Function C O F H Equipment Remark

10 FRONT AXLE

1000 Front Axle Assembly Inspect 0.5Service 1.0 2 thru 5 AReplace 5.0 6 thru 9Overhaul 10.0 K

1002 Carrier Assembly, Inspect 0.5Differential Service 0.5 2 thru 5 A


13Seal, Pinion Inspect 0.2

Replace 2.0 6 thru 9Flange, Companion Inspect 0.3


1004 Arms, Steering Inspect 0.2Replace 2.5 6 thru 9

Boot, Dust (CV) Inspect 0.3Replace 0.7 2 thru 5

Knuckle, Steering Inspect 0.1Service 0.2 2 thru 5 AReplace 2.5 6 thru 9

Axle Shaft and Inspect 0.2 2 thru 5Universal Joint Service 0.3 2 thru 5

Replace 1.511 REAR AXLE

1100 Rear Axle Inspect 0.1 0.5 AService 1.0 2Replace 4.0 2 thru 5Repair 4.0 7, 11 thru

13Overhaul 14.0 I

Rear Axle Assembly Inspect 0.3Service 0.5 2 thru 5Replace 4.0 6 thru 9Repair 4.0 6 thru 9Overhaul 14.0 K

1102 Carrier Assembly, Inspect 0.5Differential Service 0.5 2 thru 5


13Seal, Pinion Inspect 0.2

Replace 1.0 6 thru 9Flange, Companion Inspect 0.2


B-14

TM 9-2320-272-24-4


(2) (3)(4)

Maintenance Category

Component/AssemblyMaintenance

Function

(5)

Tools andEquipmentNumber

121201

1202

1206

1208

BRAKESDrum, Handbrake

Shoes, Handbrake

Linkage, Handbrake

Brakeshoes, Parking

Brakeshoes, Service

Air Manifold*

Valve, Treadle

Chamber, Service Brake

Chamber, Spring Brake

Valve, Safety Air Pressure

Valve, Front AirbrakeChamber (Limiting Valve)

Reservoir, Air Primary/Secondary

Reservoir, Air Wet TankPressure and Spring BrakeValve, Hand Control

Valves, Brake Air ControlMiscellaneous

InspectReplaceInspectAdjustReplaceRepairInspectAdjustReplaceInspectAdjust

Replace

Repair

InspectAdjust

Replace

RepairInspectReplace

InspectTestReplaceRepairInspectReplaceRepairInspectReplaceRepairInspectReplaceInspectReplaceRepairInspectReplace

InspectReplace

TestReplaceInspectReplace

0.1

0.1

0.1

0.31.50.30.52.0

0.30.51.00.51.0

3.0

0.51.0

1.5

0.10.5

0.51.0

0.7

1.0

0.10.50.10.5

0.11.0

0.21.5

0.51.00.51.0

1.0

0.5

1.0

1.5

1.0

1.0

0.3

2 thru 5

2 thru 52 thru 56 thru 9

2 thru 52 thru 5

2 thru 5192 thru 5,226 thru 9

2 thru 5,182 thru 5,216 thru 8

2 thru 5


2 thru 56 thru 9

2 thru 56 thru 9

2 thru 5

2 thru 56 thru 9

2 thru 5


2 thru 5

(6)

Remarks

A

A

A

* (M939A2 only)B-15

TM 9-2320-272-24-4


1208(Contd)

1209

1211

13 WHEELS AND HUBS1311 Hub. Wheel*

BRAKES (Contd)Valve, Brake Lock Control

Lines and Fittings,Airbrake SystemCompressor, Air

Governor, Air

Evaporator, Alcohol

Mounting and Lines,Air Compressor*

Compressor, Air*

Trailer Airbrake Connectionsand ControlsHose, Trailer Airbrake

Bearings, Wheel Hub

Wheel (M939A1/A2)

Drum, Brake

Seals, Inner and Outer Hub*

Valve Assembly, Wheel*W/Filter

MaintenanceFunction

TestReplace

InspectReplaceInspectTestReplaceRepair

InspectTestAdjustReplaceInspectServiceReplaceInspectReplace

InspectReplaceRepairInspectReplaceInspectReplace

InspectReplaceRepairInspectServiceAdjustReplace

InspectReplace

InspectReplaceRepairInspectReplace

InspectServiceReplaceRepair

Unit

C O F H Equipment

0.5 2 thru 50.5 2 thru 5

0.1 0.51.0 2 thru 5

0.10.5 2 thru 5

1.52.5

6 thru 96 thru 9

0.10.5 2 thru 50.3 2 thru 50.5 2 thru 5

0.10.2

0.5 2 thru 50.1 0.1

1.0 2 thru 50.1

3.0 2 thru 53.0 6 thru 9

0.10.3 2 thru 5

0.10.5 2 thru 5

0.11.5 2 thru 52.0 2 thru 50.51.0 20.52.5

2 thru 52 thru 5,15

0.11.0 2 thru 5,

19, 200.21.5 2 thru 5

2.0 6 thru 90.5 2 thru 52.5 2 thru 50.10.51.0

2 thru 52 thru 5

1.5 2 thru 5

A, Q

A

A

AG

A

A

A

A

A

*(M939A2 only)B-16

TM 9-2320-272-24-4

Section II. MAINTENANCE ALLOCATION CHART (Contd)(1) (2) (3) (4)


Maintenance UnitGENERALSupport Tools and


WHEELS AND HUBS (Contd)1311 Wheel (M939) Inspect 0.1 A


Hub, Wheel Inspect 0.2Replace 1.5 2 thru 5

1313 Tires Inspect 0.2 0.2 AService 0.2 A,LReplace 1.0 2 thru 5

20, 21 LRepair 1.0 2 thru 5 LRebuild 2.0 L

Tubes Replace 0.5 2 thru 5Repair 1.0 2 thru 5 L

14 STEERING1401 Link, Front Drag Inspect 0.2

Service 0.2Replace 1.0

2 thru 52 thru 5

Tie Rod Assembly Inspect 0.2Service 0.2 2 thru 5Replace 1.5 2 thru 5Repair 1.5 2 thru 5

Arm, Pitman Steering Inspect 0.1Replace 1.0 1 thru 5

Column, Steering (Lower) Inspect 0.2Replace 2.5 6 thru 9Repair 2.0 6 thru 9

Column, Steering (Upper) Replace 2.5 6 thru 9Repair 2.0 6 thru 9

Wheel, Steering Inspect 0.2Replace 1.0 2 thru 5

1407 Gear, Steering Assembly Inspect 0.2Service 0.5 1 thru 5Adjust 0.5 6 thru 9Replace 3.0 6 thru 9Repair 2.5 6 thru 9

1410 Pump, Hydraulic and Inspect 0.2Reservoir Service 0.1 A


Power Steering Pump Inspect 0.1 AAssembly Replace 1.0 2 thru 5

Repair 1.5 6 thru 91411 Lines and Fittings, Inspect 0.1 A

Power Steering Replace 1.0 2 thru 5 D

* (M939A2 only)B-17

TM 9-2320-272-24-4



Maintenance Unit General

NumberSupport Tools and

Component/Assembly Function C O F H Equipment Remarks

STEERING (Contd)1412 Cylinder, Steering Assist Inspect 0.2


15 FRAME AND TOWINGATTACHMENTS

1501 Frame Inspect 0.5Repair 1.0 2.5 6 thru 14 M

Bumper, Front Inspect 0.2Replace 2.0 2 thru 5

Brackets, Frame Inspect 0.1 AReplace 1.0 2 thru 5

1503 Pintle Inspect 0.1 AService 0.1

0.52 thru 5

Replace 2 thru 51504 Carrier, Spare Wheel Inspect 0.1 A

Replace 1.0 2 thru 51506 Wheel, 5th Inspect 0.2 A

Service 0.5 AReplace 2.5 2 thru 5Repair 2.0 6 thru 9

16 SPRlNGS AND SHOCKABSORBERS

1601 Front Spring Inspect 0.2 AReplace 3.0Repair 2.0

1 thru 52 thru 5

Shackles Inspect 0.2 AReplace 1.0 1 thru 5Repair 0.4 2 thru 5

Springs, Rear and Seat Inspect 0.1 AReplace 4.0 1 thru 5Repair 2.0 2 thru 5

1604 Absorber, Front Shock Inspect 0.1 AReplace 0.5 2 thru 5

1605 Rod, Rear Torque Inspect 0.1Replace 1.5 6 thru 9Repair 2.0 6 thru 9

18 BODY, HOOD, AND CAB1801 Doors Inspect 0.1 A

Service 0.1 2 thru 5Adjust 0.5 2 thru 5Replace 1.0 2 thru 5Repair 1.0 6 thru 10,

26Cab Inspect 0.1 A

Replace 6.0 6 thru 9 P

B-18

TM 9-2320-272-24-4


(1) (2) (3)(4)



Number Component/Assembly Function C 0 F H Equipment Remarks

BODY, HOOD, AND CAB (Contd)1801 Hood Inspect 0.1 A

(Contd) Adjust 0.5 2 thru 5Replace 2.0 6 thru 9Repair 1.0 6 thru 10 N

Cab Engine Cover Inspect 0.1 AReplace 0.5 6 thru 9

1802 Fenders Inspect 0.1 AReplace 2.0 6 thru 9Repair 1.0 6 thru 10 N

Boards, Running Inspect 0.5 AReplace 2.0 2 thru 5

1806 Cab Insulation Inspect 0.1 AReplace 2.0 2 thru 5

Seats Inspect 0.1 AReplace 1.0 2 thru 5Repair 1.0 6 thru 9 T

1810 Body, Cargo Inspect 0.2 AReplace 3.0 6 thru 9Repair 10.0 6 thru 10 C, N

Troop Seat and Racks Inspect 0.2 AReplace 1.0 2 thru 5Repair 1.0 2 thru 5

Tailgate Inspect 0.2Replace 1.0 2 thru 5Repair 2.0 6 thru 9 C, N

1812 Doors Replace 2.5 2 thru 5Repair 5.0 6 thru 10, N

26Roof, Ceiling, Sides, Floors Replace 8.0 7, 11 thruand Underframe 13

Repair 16.0 7, 10 thru N13

Mount, Front Cab Inspect 0.1Replace 2.0 2 thru 5

Mount, Rear Cab Inspect 0.1Replace 2.0 2 thru 5

Counterbalance Service 1.0 2 thru 5Replace 8.0 2 thru 5

Electrical Wiring Replace 4.0 6 thru 9Repair 4.0 6 thru 9

Heater Replace 4.0 2 thru 5Repair 1.0 6 thru 9 S

Air Conditioner Inspect 0.2 6 thru 9Replace 4.0 6 thru 9

B-19

TM 9-2320-272-24-4



Maintenance UnitNumber Component/Assembly

Tools andFunction C 0 F H Equipment Remarks

BODY, HOOD, AND CAB (Contd)1812 Boarding Ladders and Inspect 0.1

(Contd) HardwareA

Replace 0.320 HOIST, WINCH, AND

POWER TAKEOFF (PTO)

2001 Winch, Front and Rear Inspect 0.1Service

A, R0.5 2 thru 5 R

Adjust 0.5 2 thru 5Replace 3.0 2 thru 5Repair 4.0 6 thru 9Overhaul 11.0 O

Band, Automatic Adjust 0.5 2 thru 5Replace 2.0 6 thru 9

Cable, Winch Inspect 0.5 AService 0.5 RReplace 1.0 2 thru 5 RRepair 0.5 2 thru 5 R

Drum, Brake (Front Only) Adjust 1.0 2 thru 5Replace 2.0 6 thru 9

Shaft, Hydraulic Pump Inspect 0.3Drive Assembly Replace 1.0 2 thru 5

Repair 2.0 2 thru 5Lines and Fittings, Hydraulic Inspect 0.2

Replace 0.5 6 thru 9 DBoom, Assembly Inspect 0.2

Test 0.5 6 thru 9Service 0.3 2 thru 5Replace 15.0 6 thru 9Repair 8.0 6 thru 9

Hoist Cylinders and Power Replace 8.0Controls Hoist Cylinder

6 thru 9Repair 6.0 7, 11 thru

13Valve, Control Replace 2.0 6 thru 9

Repair 4.0 7, 11 thru13

Cylinder, Boom Elevating Inspect 0.2 AReplace 2.0 6 thru 9Repair 3.0 7, 11 thru

13Motor, Winch, Front Inspect 0.2

Repair 2.0 2 thru 5Cylinder, Extension Replace 3.5 6 thru 9

Repair 4.0 7, 11 thru13

Motor and Gearbox, Replace 2.0Hydraulic Swing

6 thru 9Repair 5.0 7, 11 thru

13

B-20

TM 9-2320-272-24-4


(1) (2) (3)(4)


Maintenance UnitGeneralSupport Tools and


HOIST, WINCH, ANDPTO (Contd)

2001 Winch Hoist Assembly Inspect 0.2(Contd) Service 0.5 2 thru 5 A, R


Cable, Winch Hoist Inspect 0.5 A, RService 0.5 A, RReplace 2.0Repair 0.5

Valve, Control Assembly Replace 2.5 6 thru 9Repair 4.0 6 thru 9

Motor, Hydraulic Inspect 0.2Replace 2.0 6 thru 9

Reservoir, Hydraulic Oil Inspect 0.1 AService 0.1 AReplace 2.0 6 thru 9

PTO and Winch Control Inspect 0.1 ACables* Replace 1.0 6 thru 8Hydraulic Tubing, Winch Inspect 0.1 0.2Pump* Replace 0.5 6 thru 8Propeller Shaft, Front Inspect 0.1 AWinch Dump Controls* Replace 0.8 2 thru 5

Repair 1.4 6 thru 82004 PTO, Transfer Inspect 0.1 A

Case Replace 5.0 2 thru 5Repair 2.5 6 thru 8

PTO, Transmission Inspect 0.2Replace 1.0 6 thru 9Repair 3.0 6 thru 9

PTO, Shift Linkage Adjust 0.3 2 thru 5Replace 1.0 6 thru 9

22 BODY CHASSIS ANDACCESSORY ITEMS

2201 Bows Inspect 0.1 AReplace 1.0 2 thru 5

Cover, Cab Top Inspect 0.1 AReplace 0.5 2 thru 5Repair 1.5 6 thru 9 T

Curtains, Body Cover Inspect 0.1 AReplace 1.0 2 thru 5Repair 1.0 6 thru 9 T

2202 Motor, Windshield Wiper Inspect 0.1 AReplace 0.7 2 thru 5

* (M939A2 only)B-21

TM 9-2320-272-24-4


(1) (2) (3)(4)




BODY CHASSIS ANDACCESSORY ITEMS (Contd)

2202 Arm and Blade, Windshield Inspect 0.1 A(Contd) Wiper Adjust 0.1 2 thru 5

Replace 0.2 2 thru 5Washer Bottle and Controls Service 0.1 A

Replace 1.0 2 thru 5Mirror, Rearview Inspect 0.1 A

Replace 0.5 2 thru 5Spotlight Replace 0.5 2 thru 5

Repair 0.5 2 thru 5Windshield Inspect 0.1 A

Replace 0.5 2 thru 5Heater Valves Inspect 0.1 A


2207 Heater, Personnel Inspect 0.2 AReplace 3.0 2 thru 5

33 SPECIAL PURPOSE KITS3303 Winterization Kits

Kit, Engine Coolant Heater Inspect 0.2 AInstall 10.0 6 thru 9 P

Kit, Radiator Cover Inspect 0.1 AInstall 1.2 6 thru 9 P

Kit, Hardtop Cab Inspect 0.1 AInstall 3.5 2 thru 5 P

Kit, Fuel Burning Personnel Inspect 0.2 AHeater Install 6.0 6 thru 9 PKit, Pioneer Tool Bracket Inspect 1.0 2 thru 5 PKit, Swingfire Heater Inspect 0.2 A

Install 3.6 6 thru 9 P

3305 Kit, Deepwater Fording Inspect 0.2 AInstall 3.0 6 thru 9 P

3307 Special Purpose Kits

Kit, Troop Seat and Rack Inspect 0.1 AInstall 1.0 6 thru 9 P

Kit, Air Dryer Inspect 0.2 AInstall 8.0 6 thru 9 P

Kit, A-Frame Inspect 0.2 AInstall 1.0 2 thru 5 P

Kit, Fire Extinguisher Install 1.0 2 thru 5 PMounting

Kit, Chemical Agent Alarm Install 4.0 2 thru 5 PMounting

B-22

TM 9-2320-272-24-4


(1) (2) (3)(4)


Kit, 100-Amp Alternator

Kit, Convoy Warning LightKit, European Mini-Lighting

Kit, Automatic ThrottleKit, Atmospheric Fuel TankVent SystemKit, Vehicle TiedownKit, Hydraulic HoseChafe Guard

43 CTIS SYSTEM4316 Lines and Fittings, Air*

Dryer, Air W/Filter*

4317

GroupNumber Component/Assembly

SPECIAL PURPOSE KITS (Contd)3307 Kit, Machine Gun Mounting

(Contd)

Kit, Decontamination (M13)Apparatus MountingKit, Mud GuardKit, Rifle Mounting

Kit, Hand Airbrake

Control Unit (ECU),*Electronic

Valve, Relief Safety*

Controller, Pneumatic*

Wiring Harness, Electrical*

Switch, Pressure*

Warning Light, Amber*

Seals, Air (Front and Rear)*

Maintenance UnitFunction C O

Install 3.5

Install 3.0

InstallInspectInstallInspectInstallInstall

Ins tallInstall

InstallInstall

0.50.1

2.0

0.14.02.0

4.01.4

2.55.0

InstallInstall

InspectReplaceInspectServiceReplaceRepair

InspectReplace

InspectReplaceInspectReplaceRepairInspectReplaceRepair

InspectReplaceInspectReplace

TestReplace

2.02.0

0.10.5

0.1 0.20.50.51.5

0.10.5

0.10.5

0.1 0.11.01.50.11.51.5

0.10.1

0.10.1

0.51.0

2 thru 15 P

2 thru 5 P

2 thru 5 PA

6 thru 9 PA

2 thru 5 P

2 thru 5 P

2 thru 5 P

2 thru 5 P

2 thru 5 P2 thru 5 P

2 thru 5 P2 thru 5 P

A2 thru 5 D


A2 thru 5

A2 thru 5

2 thru 52 thru 5

2 thru 52 thru 5 D

A2 thru 5

A2 thru 5


* (M939A2 only)B-23

TM 9-2320-272-24-4


(1) (2) (3)(4)




CTIS SYSTEM (Contd)4317 Filter, Compressed Air* Inspect 0.8 A

(Contd) Replace 1.0 2 thru 5Repair 1.0 2 thru 5

47 GAUGES (NON-ELECTRICAL)4701 Drive, Tachometer* Inspect 0.1 A

Replace 0.6 2 thru 5Speedometer Inspect 0.1 A

Replace 1.0 2 thru 5Tachometer Inspect 0.1 A

Replace 1.0 2 thru 54702 Gauge, Air Pressure Inspect 0.1 A


*(M939A2 only)B-24

TM 9-2320-272-24-4

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

REFERENCE MAINTENANCE(3) (4) (5)

NATIONAL/NATO TOOLCODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBER

1 O Organizational Maintenance 5180-00-762-1737 5704499Tool Kit

2 O No. 1 Common Organizational 4910-00-754-0654 SC4910-95-CL-A74Maintenance Tool Kit

3 O No. 1 Supplemental Organiza- 4910-00-754-0643 SC4910-95-CL-A73tional Maintenance Tool Kit

4 O No. 2 Common Organizational 4910-00-754-0650 SC4910-95-CL-A72Maintenance Tool Kit

5 O General Mechanic’s Tool Kit 5180-00-177-7033 SC5180-90-CL-N26

6 F Tool Kit, Direct Support 5180-00-762-1740 5704500

7 F Automotive Maintenance and 4910-00-754-0705 SC4910-95-CL-A31Repair Tool Kit

8 F Automotive Maintenance Shop 4910-00-348-7696 SC4910-95-CL-A02Equipment, Wheeled Vehicles,Set A

9 F Tool Kit, General Mechanic’s 5180-00-699-5273 SC5180-90-CL-N05

10 F Shop Equipment, Field 3470-00-357-7268 SC3470-95-CL-A08Maintenance Welding

11 H General Support Tool Kit 5180-00-762-1741 5704501

12 H No. 1 Supplemental Automotive 4910-00-754-0706 SC4910-95-CL-A62Maintenance and Repair Tool Set

13 H No. 2 Supplemental Automotive 4910-00-754-0707 SC4910-95-CL-A63Maintenance and Repair Tool Set

14 H Tool Kit, General Support 5180-01-147-5824 5704171

15 O Bearing Punch 5120-01-285-5192 20511262

16 O Air Seal Installer 5120-01-285-7620 20511263

17 O Air Gauge Assembly 5220-01-298-5730 20511320

18 O Adjusting Tool, Brakeshoe 5120-01-154-3029 J34061

19 O Tool, Wheel Assembly 4910-01-218-4490 J35193

20 O Bolt, Inserter Tool 4910-01-220-1512 J35198

21 O Pliers, Brake Repair 5120-01-152-2318 J33111

22 F Tube Reducer 4730-01-284-9086 23622

23 F Engine Barring Tool 5120-01-285-5193 3377371

24 F Wrench Box 5120-01-178-5351 CXM 1519

25 F Nozzle Cleaning Kit 2915-01-285-2527 3376947

26 F Tool Kit, Glass Cutting 5180-00-357-7737 SC4940-95-CL-A18

27 H Tube, Separation 4910-01-336-8204 KDEP-1052

28 H Puller, Side Plug 5120-01-343-2585 KDEP-1056

B-25

TM 9-2320-272-24-4

Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS (Contd)

(1) (2) (3) (4) (5)REFERENCE MAINTENANCE NATIONAL/NATO TOOL

CODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBER

29 H Tappet Holder 5120-01-345-2586 KDEP-1068

30 H Spring Compressor 5120-01-341-6000 KDEP-1505

31 H Plunger Lift Device 4910-01-338-6241 1-688-130-135

32 H Rack Extension 5340-01-341-6572 9-681-233-100

33 H Fuel Pump Test Stand 4910-01-194-7667 DFP 156

34 H Cylinder Liner Clamps 5120-01-262-7309 3822503

35 H Mechanical Puller 5120-01-291-5769 3822786

36 H Cylinder Liner Puller 5120-01-143-2032 3376015

37 H Torque Angle Gauge 5120-01-386-5992 3823878

38 H Tester, Injector Nozzle 4910-00-255-8641 7551255

39 H Puller Kit 5180-00-999-4053 J24420C

Section IV. REMARKS

REFERENCECODE

REMARKS

A Perform PMCS as shown in TM 9-2320-272-10.B Engine overhaul will be in accordance with DMWR 9-2815-500.C Welding will be in accordance with TM 9-237.D Repair of lines and fittings will be in accordance with TM 9-243.E Test and repair of radiator will be in accordance with TM 750-254.F Repair of alternator will be in accordance with TM 9-2920-225-34.G Repair of starter will be in accordance with TM 9-2920-243-34.H Repair of batteries will be in accordance with TM 9-6140-200-14.I Transmission overhaul will be in accordance with DMWR 9-2520-522.J Transfer overhaul will be in accordance with DMWR 9-2520-530.K Overhaul of front and rear axle will be in accordance with DMWR 9-2520-508.L Tires/Tubes: Repair and Inspection TM 9-2610-200-14

Storage TM 743-200-1M Repair of frames will be in accordance with TB 2300-247-40.N Metal body repair will be in accordance with FM 43-2.O Overhaul of front and rear winches will be in accordance with DMWR 9-3830-501.P Refer to kit installation instructions for kit installation.Q Inspection of brake lines will be in accordance with TB 9-2300-405-14.R Service/inspection of winch/hoist wire rope/cables will be in accordance with

TB 43-0142 and TB 9-0352.S Repair of heaters will be in accordance with TM 9-2540-205-24&P.T Repair of canvas will be in accordance with FM 10-16.U Operation of fuel pump test stand, P/N DFP 156, will be in accordance with

TM 9-4910-778-14&P.V Engine overhaul will be in accordance with DMWR 9-2815-358.

B-26

TM 9-2320-272-24-4

APPENDIX CEXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

Section I. Introduction (page C-l).Section II. Expendable/Durable Supplies and Materials List (page C-2).


This appendix lists expendable/durable supplies and materials you will need to maintain M939 seriesvehicles. This listing is for informational purpose only and is not authority to requisition listed items.

C-2. EXPLANATION OF COLUMNS

Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced inthe INITIAL SETUP of applicable tasks under the heading of MATERIALS/PARTS.

b. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listeditem.

C - Operator/CrewO - Organizational Maintenance

F - Direct Support Maintenance

C . Column (3) - National Stock Number. This is the National Stock Number assigned to the item;use it to request or requisition the item.

d. Column (4) - Description, CAGEC, and Part Number. Indicates the federal item name and, ifrequired, a description to identify the item. The last line for each item indicates the Commercial andGovernment Entity Code (CAGEC) (in parentheses) followed by a part number. These codes are identified as:

CAGEC MANUFACTURER

05972

19200

19207

Loctite Corporation

U.S. Army Research and Development CommandU.S. Army Tank-automotive and Armaments Command,AMSTA-IM-MM

58536 Federal Commercial Item Promulgated by GeneralServices Administration

62377 Permatex Industrial

71984 Dow Corning Corp.

72932 Gulf Oil Corp.

75037 Minnesota Mining and Manufacturing Company

77220 Dana Corp.

78500 Rockwell Heavy Vehicle Systems Inc.

79819 BT Office Products Intl. Inc.

80064 Naval Ship Systems Command

80244 General Services Administration

81348 Federal Specifications

C-l

TM 9-2320-272-24-4

C-2. EXPLANATION OF COLUMNS (Contd)

81349 Military Specification Promulgated by Military

81755 Lockheed Martin Company

96599 Fischbein-Dave Company96906 Military Standards96980 American Grease Stick Company97403 U.S. Army Communications - Electronic Command Center98308 Castrol Industrial North America

e. Column (5) - Unit of Issue. This column indicates the size of container issued for each NSN. Thismeasure is expressed by an abbreviation [such as ea (each), oz (ounce), gal. (gallon)]. If the unit of measurediffers from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.

C-2

TM 9-2320-272-24-4

EXPENDABLE/DURABLES SUPPLIES AND MATERIALS LIST

(1)

REFERENCECODE NO.

LEVEL NATlONAL STOCKNUMBER

O

6830-00-264-6751

(4)

DESCRIPITON

(5)

UNIT OFISSUE

ACETYLENE, TECHNICAL:gas filled acetylene,(81348) BB-A-106225 cubic feet CU-FT

2 F

3 O

4 F

5 O

6 O

7 O

8 C

9 C

10 O

ADHESIVE, LIQUID: ethylcyanacrylic resin, type II(81349) MILA-46050

0040-00-142-9193 10 1 ounce bottles per box BX

ADHESIVE, LIQUID: silicone,rubber, Silastic 732RTV (clear)non-hardening type I(81348) MMM-A-139

8040-00-262-9062 1 pint PT

ADHESIVE SEALANT: anaerobicthreadlock, medium strength,MIL-S-46163, type II, grade N,Loctite 242,(05972) 24231

8030-01-014-5869 50 milliliter ML

ADHESIVE: silicone rubber,MIL-A-46106, type I,(97403)

8040-00-833-9563 1 kit KT

ADHESIVE: syntheticrubber, class II,(80244) MMM-A-189 CL2

8040-00-543-7170 1 pint can PT

ADHESIVE: synthetic rubber,MMM-A-1617, type II,(79819) 1357

8040-00-262-9005 1 gallon can GAL.ANTIFREEZE: arctic grade,permanent type, fluorescentyellow,(81349) MILA-11755

6850-00-174-1806 55 gallon drum GAL.ANTIFREEZE: ethylene glycol,permanent type, inhibited {-60°F(-51°C)} blue-green in color,(81349) MILA-46153

6850-00-181-7929 1 gallon container GAL.6850-00-181-7933 5 gallon container GAL.6850-00-181-7940 55 gallon drum GAL.

ANTISEIZE COMPOUND:temperature resistantlubricant, MIL-A-907,Loctite, antiseize, 1050°F (566°C),(05972) 76764

8030-00-251-3980 1 pound can with brush top LB

C-3

TM 9-2320-272-24-4

EXPENDABLE/DURABLES SUPPLIES AND MATERIALS LIST (Contd)

(1) (2)

REFERENCE LEVELCODE NO.

11 O

1 2 O

13 F

14 O

15 F

16 0

17 0

18 0

19 0

20 O

21 O

22 O

2 3 O

(3) (4) (5)

NATlONAL STOCK DESCRIPITON UNIT OFNUMBER ISSUE

BAG: plastic, polyethylene,(58536) A-A-1799

8105-00-837-7754 500 bags per box BX

BOTTLES: oil sample,(81996) PD 8125-1

8125-01-082-9697 120 bott les boxper BXCALIBRATING OIL: gulf 45A,(72932) 45A

6850-00-974-3738 55 gallon drum GAL.CAP AND PLUG SET:(19207) 10935405

5340-00-450-5718 1 set SETCAULKING COMPOUND:rubber, synthetic(81349) MIL-C-18255

8030-00-682-6745 1 kit KTCHALK LINE AND REEL: self-chalking, hand crank rewind,(81349) GGG-C-291

5120-00-273-9793 50 feet EA

CHALK: marking, white,(81348) SS-C-266

7510-00-164-8893 1 gross CRCLEANING COMPOUND:windshield, concentrated(81348)

6850-00-926-2275 16 ounce bottle OZ

CLEANING COMPOUND KITengine cooling system(81349) MIL-C-10597

6850-00-598-7328 1 kit KT

CLOTH, ABRASIVE (crocus):9 inch x 11 inch sheets,(58536) A-A-1206

5350-00-221-0872 50 sheets/package PG

CLOTH, CLEANING: lint-free,general purpose, white,(81349) MIL-C-85043

7920-00-044-9281 10 pound box LB

COATING: polyurethane,chemical agent resistant, green 383,MIL-C-46168C, type II,(19207) 5584154

8010-01-160-6741 1 gallon can GAL.

COATING: battery box, non-drying epoxy,(81349) MIL-C-22750

8010-00-959-4661 1 kit KT

C-4

TM 9-2320-272-24-4


(1)

REFERENCECODE NO.

24

25

26

27

28

29

30

31

(2)

LEVEL

F

O

F

O

O

O

O

C

(3)

NATIONAL STOCKNUMBER

5330-00-069-3321

8030-00-244-1297

9150-00-265-9406

7930-00-282-9699

9150-00-935-1017

8040-01-378-02358040-00-664-4134

8040-00-728-3088

9620-00-233-6712

9150-01-197-76989150-01-197-76909150-01-197-76899150-01-197-76929150-00-530-7369

9150-00-027-2954

4720-00-845-0630

(4)

DESCRIPITON

CORK Type IB, Class 2(81348) Spec HH-C-57636 inch x 36 inch

CORROSION PREVENTIVECOMPOUND: grade II, soft film(81349) MIL-C-161731 gallon can

CUTTING FLUID:(81348) C-O-3761 gallon canDETERGENT: nonsudsing,general purpose, liquid,(80244) MIL-D-16791 type I1 gallon

GAA GREASE: automotive andartillery, MIL-G-10924,(98308) BRAYCOTE61014 ounce canGASKET COMPOUND: shellac,heavy-bodied, hard setting,(62377)2 ounce bottle1 pint bottle

GASKET SEALANT: silicone rubber,MIL-A-46106, type 1,(78500) 1199-T-38421 kit

GRAPHITE, POWDERED:MIL-SS-G-659(81348) SSG6591 pound kit

GREASE, AUTOMOTIVE ANDARTILLERY (MIL-G-10924)(81349)2-1/4 ounce tube1-3/4 pound can6-1/2 pound can35 pound can120 pound drumGREASE, SILICONE INSULATED:electric motor,(71984) Molykote DC445.3 ounce tubeHOSE: nonmetallic, rubbersynthetic, black, fuel/oil resistant(23040) C2AZ9324C3/8 inch ID, 5/8 inch OD

(5)

UNIT OFISSUE

EA

GAL.

GAL.

GAL.

OZ

OZPT

KT

KT

32 C

33 C

34 O

OZLBLBLBLB

OZ

FT

C-5

TM 9-2320-272-24-4


(1) (2) (3) (4) (5)

REFERENCE LEVEL NATIONAL STOCK DESCRIPITON UNIT OFCODE NO. NUMBER ISSUE

3 5 C

36 0

37 F

38 F

9150-00-402-2372

6850-01-160-38686850-01-287-8067

5350-00-193-1341

5350-00-271-5966

3 9 O

40 0

41 C

42 C

43 C

2640-00-256-5527

6810-00-597-36086810-00-275-6010

9140-00-286-52899140-00-286-5286

9140-00-286-52979140-00-286-5294

9140-00-286-52849140-00-286-52859140-00-286-5283

HYDRAULIC FLUID:SAE 15W40 (O-1236)(81349) MIL-L-461675 gallon canINHIBITOR, CORROSION:liquid cooling system; powder(81348) MIL-A-540091 quart bottle1 gallon bottle

LAPPING AND GRINDINGCOMPOUND: valve-grindingcompound, grease-mixed,grit 220 fine,(58536) A-A-1203 type I1 pound canLAPPING AND GRINDINGCOMPOUND: valve-grindingcompound, grease-mixed,grit 120 coarse,(58536) A-A-1203 type I1 pound canLUBRICANT, TIRE AND RIM:liquid,(96980) AA181 gallonMETHYL ALCOHOL, METHANOL:(81348) O-M-2321 gallon can5 gallon canOIL, FUEL, DIESEL DF-1: Winter(81349) (W-F-800)

gauge55 gallon drum, 18 gaugebulkOIL, FUEL, DIESEL DF-2: Regular(81348) (W-F-800)

gauge55 gallon drum, 18 gaugebulkOIL, FUEL, DIESEL DF-A: Arctic(81348) (VV-F-800)55 gallon drum, 16 gauge55 gallon drum, 18 gaugebulk

GAL.

Q TGAL.

LB

LB

GAL.

GAL.GAL.

GAL.GAL.GAL:

GAL.

GAL.GAL:

GAL.GAL.GAL.

C-6

TM 9-2320-272-24-4


(1) (2) (3) (4) (5)


44 C

45 C

46 C

47 C

48 C

49 C

50 C

51 C

52 O

9150-00-402-4478

9150-00-49 1-7197

9150-00-234-5197

9150-01-035-5390

9150-01-422-93429150-00-183-7807

9150-01-035-53939150-01-035-5394

9150-00-188-98589150-00-191-2772

9150-00-186-6668

9150-00-189-67299150-00-183-7808

9130-01-031-5816

6830-00-292-0129

OIL, LUBRICATING, ENGINE:arctic (ice, sub-zero) OEA(SEA OW-20)(19200) (9377757)1 quart can

55 gallon drum, 16 gaugeOIL, LUBRICATING, GEAR,EXPOSED: CW(81348) (W-L-751)5 pound can

OIL, LUBRICATING, GEAR,MULTI-PURPOSE: GO 75(81349) (MIL-L-2105)1 quart can

55 gallon drum, 16 gaugebulkOIL, LUBRICATING, GEAR,MULTI-PURPOSE: GO 80/90(81349) (MIL-L-2105)

5 gallon can55 gallon drum, 16 gaugeOIL, LUBRICATING, OE/HDO: 1OW(81349) (MIL-L-2104)

5 gallon drum55 gallon drum, 16 gauge

OIL, LUBRICATING: internalcombustion engine, tacticalservice, OE/HDO 10,(81349) MIL-L-21045 gallon drumOIL, LUBRICATING, OE/HDO: 30W(81349) (MIL-L-2104)55 gallon drum, 16 gaugebulkOIL, TURBINE FUEL,AVIATION: grade JP-8(81349)bulkOXYGEN, TECHNICAL: gasfilled oxygen,(81348) BB-A-925240 cubic feet (to be filled/refilledlocally)

QTGAL.GAL.

LB

QTGAL.GAL.GAL:

QTGAL.GAL:

QTGAL.GAL:

GAL.

GAL.GAL.

GAL.

CU-FT

C-7

TM 9-2320-272-24-4


(1) (2) (3) (4) (5)

REFERENCE LEVEL NATlONAL STOCK DESCRIPITON UNIT OFCODE NO. NUMBER ISSUE

53 F

9150-00-250-0933

PETROLATUM: technical, oil-solubleg r e a s e ( V a s e l i n e )(81348) W-P-2367-1/2 pound can LB

54 F

8010-00-247-4334

PIGMENT: iron, blue, oil base(substitute for Prussian blue),(81348) TT-P-3811/2 pint can PT

55 F

56 O

57 F

5210-00-640-6177

9620-00-233-6712

0010-00-145-0312

PLASTIGAGE: clearance rangegreen(77220) PG-112 each boxPOWDERED GRAPHITE:MIL-SS-G-659(81348) SSG6591 pound canPRIMER: zinc chromate(81348) Spec TT-P-17571 pint can

BX

LB

P-r

58 O

7920-00-205-1711

RAG: wiping, unbleached cottonand cotton-synthetic, mixed colors(58536) A-A-53150 pound bale LB

59 O

60 O

61 O

4020-00-23 1-2581

8105-00-290-0340

8030-00-111-6404

ROPE, FIBROUS: 3 strand,3/8 inch diameter, 1-1/8 inchcircumference, 1,350 pound capacity(81348) TR605406.667 yards, minimumSACK: shipping, water resistant,ten pound load capacity,(58536) A-A-160250 each box

SEALING COMPOUND: plasticepoxy, resin, MIL-R-46082,type II, Loctite RC/640,(05972) 6403150 cubic centimeters

YD

BX

CC62 O

8030-00-204-9149

SEALING COMPOUND: plastic,tetrafluoroethylene, Loctite 277,(05972) 59241250 cubic centimeters CC

63 C

8030-01-054-0740

SEALING COMPOUND;polyester and plastic,tetrafluoroethylene,Loctite 592-31,(05972)50 cubic centimeters CC

C-8

TM 9-2320-272-24-4


(1)

REFERENCECODE NO.

(2)

LEVEL

(3)

NATIONAL STOCKNUMBER

(4)

DESCRIPITON

(5)

UNIT OFISSUE

65 O

66 O

8030-00-247-2525

8030-00-252-3391

8030-00-180-6222

11 ounce tubeSEALING COMPOUND: non-hardening, MIL-S-45180, type II,Permatex no. 2,(80064) 175637111 ounce tubeSEALING COMPOUND: resin,synthetic, MIL-R-46082, type I,Loctite 75,(05972) 669-3150 cubic centimeters

OZ

OZ

c c67 F

68 F

69 O

70 O

71 C

72 O

73 O

8030-00-503-0316

8030-00-656-1426

6810-00-264-6618

3439-00-224-3567

6850-01-277-05956850-01-244-3207

8030-00-889-3535

5970-00-4 19-4291

SEALING COMPOUND: non-hardening, Permatex no. 51H(pipe joint compound),(77247) 51H4 ounce canSEALING COMPOUND: liquidresin, nonhardening, type III,(77247) MIL-S-451801 pint canSODIUM BICARBONATE:technical(81348) 0-5-5761 pound boxSOLDER: rosin core, 60/40,0.094 inch diagnostic,(81348) QQ-S-5715 pound spoolSOLVENT, DRYCLEANING:type III, biodegradable(81348) 134 Hi-Solv5 gallon55 gallon drumTAPE, ANTISEIZING: white,MIL-T-27730,(81755) P5025-2R1/2 inch wide x 260 inches longx 0.0035 inch thick with snap-on shellTAPE, INSULATION: electricalMIL-I-24391, 3/4 inch wide, black(75037)108 feet roll

OZ

PT

LB

LB

GAL.GAL.

EA

FT

C-9

TM 9-2320-272-24-4


(1) (2) (3) (4) (5)


74

75

76

77

78

O

F

O

O

F

5970-01-189-6927

7510-00-290-2023

6810-00-678-4418

4020-00-291-5901

TAPE, INSULATION: electrical(81349) MIL-I-243913/4 inch wide x 10 yards long x0.0085 inch thick

TAPE, PRESSURE SENSITIVE:masking, 1/2 inch wide, tan,A-A-883 type II(81348) PPP-T-4260 yards per rollTRICHLOROETHYLENE: liquid(81349) O-T-6341 gallon can

TWINE: cotton (string), 16 ply(81348) A-A-1451375 yard ball

WHITE LEAD: basic carbonate,paste in oil,(96906) MS35599-1 type B

EA

EA

GAL.

YD

79 O

80 F

81 F

82 F

8010-00-239-5736

9525-00-990-7799

9505-00-198-9125

8030-00-222-0503

5510-00-270-6031

1 pound canWIRE, NON-ELECTRICAL:safety wire(96906) QQ-N-281, Class A1 pound rollWIRE: non-electric, iron,(80244) 22-W-1642-125-361 pound rollWOOD PRESERVATIVE:(81349) MIL-S-135181 gallon canWOOD, LAMINATEDDECKING: red or white oak,ungraded, MIL-W-3912, treatedwith preservative TT-W-572,(97403) 12319E0079228 inches X 11.5 inches X 1.12inches

LB

LB

LB

GAL.

EA

C-10

TM 9-2320-272-24-4

APPENDIX DMANDATORY REPLACEMENT PARTS

Section I. Introduction (page D-l).

Section II. Mandatory Replacement Parts (page D-2).


This appendix list mandatory replacement parts you will need to maintain M939, M939A1, and M939A2series vehicles.

D-2. EXPLANATION OF COLUMNS

a. Column (1) - Item Number. This number is assigned to each entry in the listing and is referencedin the Initial Setup of applicable task under the heading of MATERIALS/PARTS.

b. Column (2) - Nomenclature. Name or identification of part.

c. Column (3) - Part Number. The manufacturer’s part number.

d. Column (4) - National/NATO Stock Number. The national stock number of the part.

D-l

TM 9-2320-272-24-4

Section II. MANDATORY REPLACEMENT PARTS

D-2

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)

NATIONAL/NATOSTOCK NUMBER

1 Adapter 3903845 5307-01-196-42462 Adapter ER22663 4730-01-127-66973 Adjuster Parts Kit 1164 2530-01-278-73644 Air Compressor Repair Kit 3801808 4910-01-272-53745 Anchor Bolt 231013398 5360-01-145-69236 Anchor Plunger Kit (Left) 11737 Anchor Plunger Kit (Right) 11748 Backing Ring 032590 5330-01-135-40699 Banjo Seal 3903380 5330-01-195-5268

10 Basic Overhaul Kit 6884259 2520-01-140-237611 Bearing 6071-2RS 3110-01-126-128712 Bearing 69867 3110-00-100-236813 Bearing Retainer 2411521 5365-01-235-258014 Bearing Shell 214950

214951214952214953

3120-01-087-30043120-01-155-44423120-01-157-33163120-01-155-8707

15 Brake Band 7409663 2530-00-740-966316 Brakeshoe Lining 2740-D-1122 2530-01-135-018717 Brakeshoe Lining and

Assembly Kit2000-P-1446 2530-01-326-6127

18 Breakoff Screw 2 423 450 005 5305-01-336-000619 Breakoff Screw 1 423 450 056 5305-01-301-511220 Breakoff Screw 2 910 172 197 5305-01-335-996521 Bushing S1003A 5326-00-598-525522 Bushing 55602H 3120-00-740-934423 Bushing S1077 5365-00-362-188024 Bushing 7411156 3120-00-741-115625 Bushing 7409666 3120-00-740-966626 Bushing 7954534 3120-01-120-845027 Bushing 23011924 4730-01-078-273228 Bypass Disc 200819 4820-00-400-518929 Bypass Seat 153526 2815-00-131-170030 Bypass Spring 251152 5360-00-932-745231 Bypass Valve 3902338 2815-01-211-5270

TM 9-2320-272-24-4

Section II. MANDATORY REPLACEMENT PARTS (Contd)

D-3

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


32 Camshaft Bore Cork Gasket 9333-1 5330-00-729-4427

33 Camshaft Bushing 100670 3120-00-573-0391

34 Camshaft Bushing 157870 3120-00-906-6657

35 Chamfered Washer 23014094 5310-01-145-6923

36 Channel Seal 7373291-2 5330-01-026-7512

37 Checkball 8622757 2520-00-008-730638 Compression Ring 187350 4310-01-197-1882

39 Compression Ring 650330 4310-01-079-5245

40 Connecting Rod Bearing 3901434 3120-01-275-7665

41 Connector MS27144-1 5935-00-167-7775

42 Copper Washer 007603014106 5330-12-156-4523

43 Cooper Washer 3912889 5310-01-271-5706

44 Copper Washer 2916710613 5325-01-276-8488

45 Copper Washer 2916710619 5330-01-301-1763

46 Cotter Pin MS24665-283 5310-00-842-3044

47 Cotter Pin MS24665-500 5310-00-187-9567

48 Cotter Pin 210492 5310-01-246-4339

49 Cotter Pin MS24665-362 5310-00-298-1498

50 Cotter Pin MS24665-134 5315-00-839-5820

51 Cotter Pin IF316 5315-00-816-1794

52 Cotter Pin MS2466-172 5315-00-187-9370

53 Cotter Pin AN415-4 5315-01-057-8371

54 Cotter Pin MS24655-490 5315-00-059-0205

55 Cotter Pin MS24665-214 5315-00-080-3503

56 Cotter Pin MS24665-353 5315-00-839-5822

57 Cotter Pin MS24665-351 5315-00-893-5821

58 Cotter Pin MS24665-369 5315-00-059-0187

59 Cotter Pin MS24665-498 5315-00-849-985460 Cotter Pin MS24665-335 5315-00-012-012361 Cotter Pin MS24665-361 5315-00-059-0184

62 Cotter Pin MS24665-300 5315-00-234-186363 Cotter Pin MS24665-655 5315-00-187-941464 Cotter Pin MS24665-493 5315-00-018-798865 Cotter Pin AN415-6 5315-01-018-9991

TM 9-2320-272-24-4


D-4

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


66 Cotter Pin MS24665-132,A82-1

5315-00-839-2325

67 Cotter Pin MS34665-627 5315-00-013-730868 Cotter Pin MS24665-502 5315-00-849-558269 Cotter Pin MS24665-423 5315-00-013-722870 Cotter Pin MS24665-381 5315-00-839-232671 Cotter Pin MS24665-427 5315-00-879-291072 Cotter Pin MS24665-491 5315-00-059-020673 Cotter Pin L6451-101 5315-00-187-959174 Cotter Pin MS24665-631 5315-00-597-739975 Cotter Pin MS24665-49 5315-01-136-454276 Cotter Pin MS24665-359 5315-00-013-721477 Cotter Pin MS24665-628 5315-00-846-012678 Cotter Pin MS24665-238 5315-00-239-802779 Cotter Pin 137159 5315-00-013-715980 Cotter Pin CO2-40-4 5315-01-135-950681 Cotter Pin MS24665-5 5315-00-236-834582 Cotter Pin MS24665-285 5315-01-359-145183 Cotter Pin MS24665-153 5315-00-185-003784 Cotter Pin MS24665-151 5315-00-815-140585 Cotter Pin MS24665-357 5315-00-298-148186 Cotter Pin 20511322Z 2530-01-272-291287 Cotter Pin 3801260 3120-01-132-933988 Cotter Pin 215090 5330-00-064-439989 Cotter Pin 175831 5340-00-485-094590 Cotter Pin 7084738 2590-00-471-534391 Cotter Pin 8380498 2590-00-471-534492 Cotter Pin A-3261-S-253 3040-01-149-111193 Cotter Pin 39041594 Cotter Pin 3076189 5330-01-080-502195 Cotter Pin 3917737 5330-01-272-128296 Cotter Pin 69519 5315-00-475-251497 Cotter Pin 70550 2815-01-124-023298 Cotter Pin 3917883 5315-01-270-8286

TM 9-2320-272-24-4

Sect ion II . MANDATORY REPLACEMENT PARTS (Contd)

(1) (2) (3) (4)

ITEM NOMENCLATURE PART NATIONAL/NATONO. NUMBER STOCK NUMBER

99 Dowel Pin 3904483 5315-01-270-8285

100 Dowel Ring 60575 5365-00-428-6201

101 Drive Pin S-2286 5305-00-804-6318

102 Drivebelt 3912004 3030-01-217-3754

103 Dustcap Assy DCL6N-3

104 Dustcap Assy SERUR14-16 2530-01-286-0108

105 Expansion Plug 3032693 5340-01-271-2420

106 Expansion Plug 156075 5340-01-271-2419

107 Expansion Plug 3900965 5340-01-194-8936

108 Fan Drive Repair Kit F212028

109 Fastener 7529309 2540-00-562-0422

110 Felt Seal 7411160 5330-00-741-1160111 Felt Washer 5X625 5330-00-740-9312

112 Felt Washer 7409928 5310-00-740-9928113 Felt Washer 7417093 5330-00-741-7093

114 Felt Washer 7409929 5330-00-740-9929

115 Felt Washer 7411154 5330-00-741-1154

116 Felt Washer 7411159 5330-00-741-1159

117 Felt Washer 7417094 5330-00-741-7094

118 Ferrule 2297-N-5630 4730-01-272-0582

119 Fiber Washer 14079550 5330-00-107-3925

120 Filter 3313281 2940-01-157-6309

121 Fi l ter 146483 2910-00-790-8736

122 Filter 599791 4460-01-284-2344

123 Filter Element Kit ERS-28001 4330-01-272-2937

124 Filter Element Kit 12503 4330-01-284-6203

125 Filter Kit AR 51480 2940-00-404-3057

126 Filter Screen 23010654 2940-01-140-8227

127 Filter Strip 12277066 9320-01-109-5696

128 Fluid Pressure Kit 3652-11 4330-01-243-0055

129 Fluid Pressure Kit 256476 2910-00-152-2033

130 Flywheel Seal Ring 6770492 5330-00-999-3760

131 Frame Seal 7373300 9390-00-737-3300

132 Freeze Plug 213394 5310-01-087-0682

D-5

TM 9-2320-272-24-4


165 Gasket 1227128 5330-01-115-0604

( 1 ) (2) (3) (4)

ITEM PARTNO.

133 Freeze Plug 213395 5340-01-087-0681

134 Freeze Plug 216524 5340-012-086-6193135 Fuel Filter 33472 2910-01-201-7719136 Fuel Injection Pump 57k0144 2910-01-339-0423

Maintenance Kit

137 Fuel Injection Pump Repair Kit 1417010008 2910-01-339-7912

138 Gasket 3048341 5330-01-262-5118139 Gasket 3923054 5330-01-190-9555140 Gasket 3911941 5330-01-272-1146

141 Gaske t 3914388 5330-01-190-1905142 Gasket 1235675 5330-01-299-6616

143 Gasket 7539072 5330-00-753-9072144 Gasket A5711 5310-01-133-5847

145 Gasket 153518 5330-01-044-2096146 Gasket 154088 5330-00-961-9470

147 Gasket 70441 5330-00-508-0411

148 Gaske t 3060912 5330-01-272-1142

149 Gasket 3914310 5330-01-287-8656

150 GASKET 3913032 5330-01-901-1828151 GASKET 3913025 5330-01-302-0780152 GASKET 35913027 5330-01-301-1829153 GASKET 130226 5330-00-106-6370

154 GASKET 3914391 5330-01-272-1138155 GASKET 1164431 5330-00-143-7797156 GASKET 11664480 5330-00-252-3274

NOMENCLATURE NATIONAL/NATONUMBER STOCK NUMBER

157 Gasket 33069823 5330-01-137-4487

158 Gasket 3031007 5330-01-165-2314

159 Gasket 29501160 5330-01-120-8090

160 Gasket 3905449 5330-01-271-8307

161 Gasket 7979274 5330-00-740-9600

162 Gasket 3910642 5330-01-271-8306

163 Gasket 154916 5330-01-071-5727

164 Gasket 7979275 5330-00-734-6993

D-6

TM 9-2320-272-24-4


(1) (2) (3) (4)

NOMENCLATURE PARTNUMBER


ITEMNO.

166 Gasket I 1089995 I 5330-00-182-3489

167 Gasket I 65274 5330-00-246-0309

5330-00-659-3178

5330-00-193-7652

5330-01-379-4345

5330-01-267-0399

5330-00-861-8592

5330-01-147-4071

Gasket 142234

Gasket 134276

Gasket 12255817

Gasket 3011273

Gasket 3017750

Gasket 307613

168

169

170

171

172

173

174 Gasket 151911 5330-00-961-6314

5330-01-374-0400

5330-00-465-5818

5330-00-143-8371

5330-00-143-8376

Gasket 12256082-1

Gasket 134285

Gasket 110453

Gasket 157551

Gasket 68210

175

176

177

178

179

180

5330-00-328-8656

Gasket 3008017 5330-01-079-6514I

Gasket 3008591 5330-01-086-3523

Gasket 3012972 5330-01-131-2967

181

182

183

184

185

Gasket 3069101 5330-00-026-2931

Gasket 70089-l 5330-00-537-2382

Gasket 320-1850 5330-01-181-0631

Gasket 154018 5330-00-852-7347

Gasket 3054841 5330-01-285-4827

Gasket 3921852 5330-01-272-1145

186

187

188

189 Gasket 3908096 I 5330-01-266-3294

190 Gasket 3914301 I 5330-01-271-4308

191 Gasket 3929253 I 5330-01-317-3213

192 Gasket 3915772 5330-01-263-6179

Gasket 3914017 5330-01-289-3135

Gasket 3914302 5330-01-272-1143

Gasket 3917780 5330-01-321-2053

Gasket 3911942 5330-01-281-9013

Gasket 3915800 5330-01-270-8144

Gasket 3201386 5330-01-181-0630

193

194

195

196

197

198

199 Gasket 176027 5330-00-129-9389

D-7

TM 9-2320-272-24-4


(1)

ITEMNO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


200 Gasket 3047159 5330-00-131-7072

201 Gasket 12302621 5330-01-232-1487

202 Gasket 7376584 5330-00-737-6584

203 Gasket 3021735 5330-01-082-6985

204 Gasket 50161-2 5330-01-285-1601

205 Gasket 6884872 5330-01-111-9291

206 Gasket 10900396 5330-00-419-5872

207 Gasket 7346886 5330-00-734-6886

208 Gasket 7346896 5330-00-641-2466

209 Gasket 291882 5330-01-123-6409

210 Gasket 20510093-4Z 5330-01-271-9407

211 Gasket 11663365 5330-01-054-4011

212 Gasket 7973339 5330-00-895-3424

213 Gasket 7409821 5330-00-740-9821

214 Gasket 7409822 5330-00-057-3823

215 Gasket 3914308 5330-01-271-6404

216 Gasket 7409933 5330-00-740-9933

217 Gasket 7409931 5330-00-166-4333

218 Gasket 7409932 5330-00-740-9932

219 Gasket 20511420 5330-01-361-5600

220 Gasket 2208-U-697 5330-00-549-7694

221 Gasket 35-P-8 5330-00-485-0895

222 Gasket 22-P-24-2 5330-00-485-0865

223 Gasket 70705 5330-00-562-1176

224 Gasket 12288013 5330-00-781-7774

225 Gasket 6771366 5330-00-911-9411

226 Gasket 23016347 2840-01-068-1713

227 Gasket 23014221 5330-00-557-6518

228 Gasket 23045099 5330-01-219-2555

229 Gasket 11592566 5330-00-414-6695

230 Gasket 3918174 5330-01-271-5791

231 Gasket 7535583 5330-00-415-1484

232 Gasket 830431 5330-00-415-1488

233 Gasket 10876133 5330-00-826-5202

D-8

TM 9-2320-272-24-4

NOMENCLATURE PART NATIONAL/NATONUMBER

(1) ( 2 ) (3) (4)

ITEMNO.

234 Gasket 10876132 5330-00-826-5203

235 Gasket 7529300 5365-01-129-0399

236 Gasket MS51071-7 6680-00-882-0965

237 Gasket 981072 5220-00-982-4259

238 Gasket 35-P-41 5330-01-133-0205

239 Gasket 100764 5330-00-506-4866

240 Gasket 173086 5330-00-132-0247

23011670241 Gasket 5330-00-001-1984

242 Gasket 118394

243 Gasket 3008947 5330-01-129-6541

244 Gasket HFB642010-A1

245 Gasket 3780-Q-381 5330-01-292-9575

246 Gasket 2208-S-1033 5330-01-272-1148

247 Gasket and Seal Set 5518441 5330-01-341-6583

248 Gasket and Shim Set 7346807 5330-00-513-1443

249 Governor Filter 6882687 4330-01-074-9642

250 Governor Filter O-ring 6882689 5330-01-080-3254

251 Grommet 7035447, 5340-00-264-7182747R

252 Grommet MS35489-135 5325-00-263-6648

253 Half-Keeper 127554 5340-01-143-6048

254 Hi-Lo Shaft Seal A-1205-P-1758 5330-01-132-8346

255 Injector Overhaul Kit AR-51522 2910-00-117-3689

256 3909886 2910-01-271-9826Injector Sleeve

257 Injector Sleeve 3011934 2910-01-146-0048

258 Inner Seal Ring 23011471 4310-01-006-4952

259 Inner Seal Ring 6883031 5330-01-083-3065

260 Insulation 12302774

261 Insulator 11669319-1 5970-01-114-3753

262 I n s u l a t o r 12256707 5340-01-104-7843

263 Isolator 11669109 5340-01-101-0005

264 J a m n u t MS51967-18 5310-00-763-891951967-18

265 K e y 8327444 5315-00-281-7652


STOCK NUMBER

D-9

TM 9-2320-272-24-4


(1)

ITEMNO.

266

267

268

269

270

271

272

273

274

275

(2)

NOMENCLATURE

Key

Key Washer

Keyway Insert

Leather Washer

Load Check Valve Kit

Lock Pin

Locknut

Locknut

Locknut

Locknut

(3) (4)

PART NATIONAL/NATONUMBER STOCK NUMBER

7535631 5315-01-217-2269

114638 5310-00-887-8325

5-X-663 5330-01-133-7262

77121-l 5310-00-760-7493

5704273 4820-01-093-5785

10166 5315-01-284-9812

MS21045-4 5310-00-061-7325

MS51943-46 5310-00-935-3569

MS21045-3 5310-00-061-7326

MS51922-5 5310-00-959-7600276 Locknut MS21044N4 5310-00-877-5796

277 Locknut MS51922-13 5310-00-984-3807

278 Locknut 5590560 5310-01-126-9404

279 Locknut 942279 5310-01-193-6884

280 Locknut MS51922-9 5310-00-984-3806

281 Locknut MS21045-7 5310-00-274-9364

282 Locknut MS21245-L10 5310-00-449-2381

283 Locknut MS21044-N3 5310-00-877-5797

284 Locknut MS51922-17 5310-00-087-4652

285 Locknut MS21045-8 5310-00-062-4952

286 Locknut MS51922-61 5310-00-832-9719

287 Locknut 1779-Z-260 5310-00-949-6280288 Locknut MS51922-21 5310-00-959-1488

289 Locknut 3913371 5310-01-287-5742

290 Locknut 12301125 5310-01-210-0199

291 Locknut MS51943-36 5310-00-814-0672

292 Locknut MS21045-C3 5310-00-263-2862

293 Locknut MS17830-06C 5310-00-176-6341

294 Locknut MS51943-40 5310-00-488-3888

295 Locknut MS51943-39 5310-00-488-3889

296 Locknut MS51922-53 5310-00-225-6408

297 Locknut MS51922-1 5310-00-088-1251

298 Locknut MS51968-8 5310-00-732-0559

299 Locknut MS51943-34 5310-00-241-6658

D-10

TM 9-2320-272-24-4


(2)

NOMENCLATURE

(3) (4)

PART NATIONAL/NATONUMBER STOCK NUMBER

MS51922-6 5310-00-143-6102

9422305 5310-01-130-4274

8712289-5 5310-00-044-3342

3906216 5310-01-270-8251

MS51943-33 5310-00-814-0673

FCO30005 5310-01-270-8342

MS51943-35 5310-00-935-9021

AN365-1024A 5310-00-208-1918

7373244 5310-00-269-7044

MS21044-N8 5310-00-877-5795

MS21045-10 5310-00-982-5009

MS21045-12 5310-00-982-5012

MS51922-37 5310-00-067-9507

MS51943-32 5310-00-935-9022

MS21083C12 5310-00-923-4219

MS51943-38 5310-00-994-1006

MS21045-14 5310-00-982-5014

11609727-2 5310-00-176-6690

MS21045-5 5310-00-982-4912

9422301 5310-01-149-4407

1227-K-1051 5310-01-099-0397

MS51943-44 5310-00-241-6664

MS51943-2 5310-01-374-0508

NAS1021-N17 5310-00-325-1900

3311501033 5310-01-143-0512

2304890 5310-00-748-0548

S-212 5310-00-011-7051

MS21045-6, 5310-00-982-4908456702

9419479 5310-01-409-1642

MS51943-5 5310-01-249-0904

9422298 5310-01-150-5914

MS21045-18 5310-00-057-7153

G-9415992 5310-00-421-3991

(1)

ITEMNO.

Locknut

Locknut

Locknut

300

301

302303

304

Locknut

Locknut

Locknut

Locknut

305

306

Locknut

Locknut

Locknut

307

308

309

310 Locknut

311 Locknut

312 Locknut313 Locknut

314 Locknut

315 Locknut

316 Locknut

Locknut

Locknut

Locknut

317

318

319

320 Locknut

321 Locknut

322 Locknut

323 Locknut

324 Locknut

325 Locknut

326 Locknut

327 Locknut

328

329

330

331332

Locknut

Locknut

Locknut

Locknut

Locknut

D-11

TM 9-2320-272-24-4


NOMENCLATURE PART NATIONAL/NATONUMBER STOCK NUMBER

(1) ( 2 ) ( 3 ) ( 4 )

ITEMNO.

333 Locknut MS519221-1 5315-00-088-1251

334 Locknut 131245 5310-00-013-1245

335 Locknut MS21042-8 5310-00-807-1468

336 Locknut MS51943-4 5310-00-935-3750

337 Locknut MS51943-6 5310-01-344-8250

338 Locknut MS51943-10 5310-00-455-9967

339 Locknut 109319 2518-00-406-8936

340 Lockplate 3914708 5310-01-330-8313341 Lockplate 3039305

342 Lockstrap 6880899 5340-01-056-0037

343 Locktab 028426 5310-01-135-6758

344 Locktab Washer 8758258 5310-00-147-3274

345 Lockwasher MS35335-33 5310-00-209-0786

346 Lockwasher MS35338-62 5310-00-274-8710

347 Lockwasher MS35338-63 5310-00-274-8715348 Lockwasher MS12203-2 5310-00-159-6209349 Lockwasher MS35338-8, 5310-00-261-7340

S-604

350 Lockwasher 210104-8S 5310-00-003-4094

351 Lockwasher MS35338-42 5310-00-045-3299

352 Lockwasher MS35338-43 5310-00-045-3296

353 Lockwasher MS45904-73

354 Lockwasher MS35338-46 5310-00-130-9065

355 Lockwasher MS35333-44 5310-00-194-1483

356 Lockwasher MS35335-42 5310-00-595-7237

357 Lockwasher MS35335-32 5310-00-596-7691

358 Lockwasher MS27183-14 5310-00-080-6004

359 Lockwasher 138485

360 Lockwasher MS353335-35, 5310-00-627-6128138489

361 Lockwasher WA-LH8-3 5310-00-031-2673362 Lockwasher MS35338-52 5310-00-754-2005363 Lockwasher MS35043-53 5310-00-926-5885

364 Lockwasher 7410218, 5310-00-407-9566MS35338-45

D-12

TM 9-2320-272-24-4


NOMENCLATURE NATIONAL/NATONUMBER STOCK NUMBER

(1) (2) ( 3 ) (4)

ITEM PARTNO.

365 Lockwasher 1229-S-513-C 5310-01-062-3384

366 Lockwasher MS35333-49 5310-00-582-6714

367 Lockwasher MS35333-41 5310-00-167-0721

368 Lockwasher MS35340-48 5310-00-834-7606

369 Lockwasher MS35335-31 5310-00-596-7693

370 Lockwasher 2379-10ZF 5310-01-135-4828

371 Lockwasher MS35333-40 5310-00-550-1130

372 Lockwasher MS45904-84 5310-00-935-8984

373 Lockwasher MS35335-30 5310-00-209-0788

374 Lockwasher MS35338-41 5310-00-045-4007

375 Lockwasher MS35333-47 5310-00-550-3714

376 Lockwasher MS35340-43 5310-00-721-7809

377 Lockwasher MS35338-50 5310-00-820-6653

378 Lockwasher MS35333-78 5310-00-261-7156

379 Lockwasher MS45904-76 5310-00-061-1258

380 Lockwasher 3910266 5310-01-270-8423

381 Lockwasher MS35338-49 5310-00-167-0680

382 Lockwasher MS35338-47 5310-00-209-0965

383 Lockwasher 3912897 5310-01-270-8405

3 8 4 Lockwasher MS35336-9 5310-00-550-0248

3 8 5 Lockwasher MS35335-34 5310-00-510-6674

386 Lockwasher 9 6 9 0 6 5310-00-959-4679

387 Lockwasher 06853 5310-00-119-4864

388 Lockwasher MS35335-40 5310-00-275-3683

389 Lockwasher MS35333-39 5310-00-576-5752

3 9 0 Lockwasher AN3066-12 5975-00-793-5550

3 9 1 Lockwasher MS35233-38 5310-00-559-0070

392 Lockwasher MS35338-50 5310-00-004-5034

393 Lockwasher MS35338-51 5310-00-584-7888

394 Lockwaasher 378003 5310-00-838-1490

395 Lockwasher 9411417 5310-00-799-4910

396 Lockwasher 2 916 699 092 5310-01-300-7037

397 Lockwasher 2 916 699 085 5310-01-301-1875

3 9 8 Lockwasher 2 916 699 083 5310-01-301-7811

D-13

TM 9-2320-272-24-4

(1)

ITEMNO.

399 Lockwasher

400 Lockwasher

401 Lockwasher

402 Lockwasher

403 Lockwasher

404 Lockwasher

405 Lockwasher

406 Lockwasher

407 Lockwasher

408 Lockwasher

409 Lockwasher

410 Lockwasher

411 Lockwasher

412 Lockwasher

413 Lockwasher

414 Lockwasher

415 Lockwasher

416 Lockwasher

417

418

419

420

421

422

423

424

425

426

427

428

429

430

Lockwasher

Lockwasher

Lockwire

Lockwire

Lockwire

Lubrication Valve

Manifold PressureCompensator Maintenance Kit

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

D-14


(2)

NOMENCLATURE

(3)

PARTNUMBER

MS35335-39

MS35338-44

26X-3074

MS45904-68

20X-0196

MS45904-72

MS35335-36

MS35335-60

181466

S-622

WA-LM7-2

MS35336-39

S-610

S-606

178556

120380

11500207

1613,MS35338-48

MS51848-14

MS45904-74

22-W-1642-100

MS20995F9H2

MS20995F91

6834624

57K0143

(4)


5310-00-800-0695

5310-00-582-5965

5310-00-889-2528

5310-00-889-2527

5310-00-550-3503

5310-00-209-1239

5310-00-484-1718

5310-00-562-6557

5310-00-486-5355

5310-00-194-9213

5310-01-300-8400

5310-00-410-6756

5310-00-017-8556

5310-00-209-2946

5310-01-206-7306

5310-00-584-5272

5310-00-171-1735

9505-00-554-0098

9505-00-846-0941

2520-00-557-5900

2910-01-339-0422

145504 5330-01-051-4243

130240 5330-00-106-6969

15434 5330-01-272-1123

3910824 5330-01-281-8997

MS28775-032 5330-01-049-7374

6762127 5330-01-010-9693

MS28778-10 5330-00-285-9842

TM 9-2320-272-24-4


D-15

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


431 O-ring 3909397 5330-01-272-1120

432 O-ring 12301126 5330-01-210-2155

433 O-ring MS35489-6 5325-00-263-6632

434 O-ring N72259 5330-00-152-1759

435 O-ring N72260 5330-01-166-3662

436 O-ring MS28775-238 5330-00-579-75745

437 O-ring AN6290-6 5330-00-804-5695

438 O-ring 131026 5330-00-143-8485

439 O-ring 137075 5330-00-420-9624

440 O-ring 67270 5330-00-171-3879

441 O-ring 3019116 5330-01-160-7458

442 O-ring 70624 5330-00-506-4874443 O-ring 3024789 5330-01-145-5381444 O-ring 3910260 5330-01-272-1124445 O-ring 3913994

TS33-016 705330-01-291-6537

446 O-ring 3910503 5330-01-272-1121447 O-ring 3916284 5330-01-272-1122448 O-ring FCO30020 5330-01-271-9372449 O-ring FD76A 5330-01-123-2832450 O-ring FD145A 5330-01-271-9374451 O-ring FD0077 5330-01-079-6513452 O-ring 233955 5330-00-074-2692453 O-ring ER-82141 5330-01-129-0384454 O-ring MS29513-115 5330-00-248-3847455 O-ring MS28775-219 5330-00-579-7925456 O-ring MS28775-225 5330-00-579-7927457 O-ring MS28778-12 5330-00-251-8839458 O-ring 154129 5330-00-948-6482459 O-ring MS28775-113 5330-00-582-2855460 O-ring 3032874 5330-01-220-2389461 O-ring 68061-A 5330-00-970-3461462 O-ring 100478 5330-00-081-9289463 O-ring 213768 5330-01-072-8983

TM 9-2320-272-24-4


D-16

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


464 O-ring 582826 5330-00-522-8544

465 O-ring MS28775-249 5330-01-019-2448

466 O-ring M83461/1-427 5330-01-183-0985

467 O-ring MS28775-243 5330-00-579-7544

468 O-ring MS28778-20 5330-00-816-3546

469 O-ring MA28775-128 5330-00-702-5643

470 O-ring AS3551-12 5330-00-776-2830

471 O-ring MS28775-232 5330-00-585-8247

472 O-ring MS27183 5310-01-317-1812

473 O-ring 7374401 5330-00-984-3756

474 O-ring 20510736 4730-01-279-1519

475 O-ring 154087 5330-00-772-7657

476 O-ring 3037236 5330-01-331-9293

477 O-ring MS28778-8 5330-00-808-0794478 O-ring 3007759 5330-01-072-4436479 O-ring 282818 5330-01-217-0734480 O-ring 18048 5330-01-280-6503481 O-ring 028466 5310-01-135-6754482 O-ring 032586 5330-01-143-2780483 O-ring 032616 5330-01-149-7229

484 O-ring 032571 5330-01-135-4809485 O-ring 032615 5330-01-135-4068486 O-ring M83461/1-012 5330-01-046-3300487 O-ring MS28775-206 5330-01-133-5858488 O-ring M832484/1-324 5330-01-005-3704489 O-ring MS28778-16 5330-00-804-5694490 O-ring M83461/1-219 5330-01-128-3954491 Oil Filter PH3519 2940-01-110-2489492 Oil Filter Element PF297 2940-00-950-8410493 Oil Pan Gasket 3032861 5330-01-147-0748494 Oil Pump Kit 3802278 2815-01-268-8753495 Oil Seal A-1205-E2137 5330-01-271-9362496 Oil Seal 10938292 5330-00-145-8355

TM 9-2320-272-24-4


D-17

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


497 Oil Seal 4591SCR,A-1205-Z-2132

5330-01-271-9410

498 Oil Seal 211255 5330-00-135-6382

499 Oil Seal 208069 5300-00-006-2529

500 Oil Seal A-1205-U-1737 5330-01-023-0269

501 Oil Seal 28-P-52 5330-00-237-7828

502 Oil Seal 23016643 5330-01-219-2375

503 Oil Seal 6773311 5330-00-999-3752

504 Oil Seal A-1205-U-1633 5330-01-126-0565

505 Oil Seal Kit 3802387

506 Oil Seal Kit 3802389 5330-01-344-0567

507 Oil Sleeve 1844-J-634 2520-01-132-6841

508 Outer Bearing Oil Seal 7431447 5330-00-961-3596

509 Outer Seal Ring 6883035 5330-01-104-8934

510 Packing 10900300 5330-00-523-4235

511 Packing 11609215 5330-00-269-4953

512 Packing 032634-A1 5330-01-135-0682

513 Packing Ring 032361 5330-01-195-5757514 Pin 7412376 2510-00-741-2376515 Piston Inner Seal Ring 23015880 5330-01-146-6053516 Piston Outer Seal Ring 6833981 5365-01-010-9689517 Piston Ring 180810 2815-01-079-3290518 Piston Rings 3802110 2815-01-271-9792519 Piston Seal 10900304 5340-00-523-4305520 Piston Seal Ring 6758740 5330-00-582-0456521 Plastic Backup Washer 028435 5310-01-161-6131522 Power Steering Filter Kit ERS27788 2530-01-137-5921523 Power Steering Parts Kit 20510093-26Z 2530-01-272-2910524 Pressure Regulator Plunger 391852 5340-01-331-9625525 Pumping Element Kit 20510093-25Z 5330-01-271-9544526 Rear Cover Plate Gasket 151623 5330-01-082-1906527 Rear Cover Plate Seal M39807 5330-00-005-0858528 Regulator Channel Filler 10906350 2510-00-179-5708529 Regulator Channel Seal 7373301 9390-00-737-3301

TM 9-2320-272-24-4


D-18

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


530 Relay Valve Kit 599913 2530-01-284-4287

531 Relay Valve Kit 599911 2530-01-284-4288

532 Relief Fitting 70295 4730-00-011-3175

533 Relief Valve Kit 5704274 2590-00-606-2383

534 Repair Kit 3011472 5330-00-480-6133

535 Repair Kit AR73350 2815-00-913-2074

536 Resilient Mount 7521436 5340-00-040-2073

537 Retaining Ring 110827 5330-00-785-7894

538 Retaining Ring MS16625-1100 5365-00-807-2636

539 Retaining Ring 3901996 5325-01-280-5592

540 Retaining Ring 401309 5325-00-613-7796

541 Ring Seal 900877 2590-01-119-4103542 Rivet MS20600AD6W4 5320-00-528-3276543 Rivet 7B5049 5320-00-262-6492544 Rivet RV876 5320-01-146-9582545 Rivet MS20600-MP8W/4 5320-01-068-2340546 Rivet MS20600AD5W2 5320-00-582-3302547 Rivet RV200-6-3 5320-00-582-3268548 Rivet MS20600AD8W7 5320-00-721-5384549 Rivet MS24662-234 5320-00-930-7865550 Rivet RV200-6-4 5320-00-582-3276551 Rivet RV200-6-2 5320-00-584-1285552 Rivet MS20470A6-6 5320-00-242-1580553 Rivet ADJUST644 5320-00-956-7355554 Rivet MS20470A5-8 5320-00-234-8557555 Rivet MS20473A6-9 5320-00-264-3266556 Rivet CR9163-6-6 5320-00-582-3499557 Rivet RV200-6-1 5320-00-616-4350558 Rivet MS24661-226 5320-00-231-3663559 Rivet RV200-6-5 5320-00-582-3301560 Rod Seal MS28775-222 5330-00-338-4460561 RQV Governor Cover Housing

Maintenance Kit57K0141 2910-01-338-4460

562 RQV Governor Cover Maintenance Kit 57K0142 2910-01-338-6473

TM 9-2320-272-24-4


D-19

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


563 Rubber Bumper 7535643 5340-00-766-3330

564 Rubber Bushing 7409618 5365-00-740-9618

565 Rubber Grommet MS35489-19 5325-00-276-6091

566 Rubber Seal 12256106 5330-01-120-8454

567 Safety Wire ASTM AS41 9505-00-248-9842

568 Safety Wire 22W1642125 9505-00-198-9125

569 Screw MS90726-97 5305-00-225-9092

570 Screw MS51106-421 5305-00-940-9517

571 Screw 522875572 Screw-Assembled Lockwasher 425841 5306-00-042-5841573 Screw-Assembled Lockwasher 187995,

73732715305-00-696-5285

574 Screw-Assembled Lockwasher 455176 5305-01-225-2106



577 Screw-Assembled Lockwasher 423569 5306-01-226-0798578 Screw Assembled Lockwasher 70772 5305-00-477-6769579 Screw-Assembled Lockwasher 3021470 5305-01-144-6233580 Screw-Assembled Lockwasher 3012472 5305-01-112-4312581 Screw-Assembled Lockwasher 7372083-1 5305-01-090-7626582 Screw Assembled Lockwasher MS90726-59 5305-00-912-5113583 Screw Assembled Lockwasher 423568 5305-00-042-3568584 Screw Assembled Lockwasher 11663070 5305-01-104-9018585 Screw Assembled Lockwasher 11664479-1 5306-01-106-3850586 Screw Assembled Lockwasher 3010593 5305-01-197-3449587 Screw Assembled Lockwasher 423518 5305-00-638-0714588 Screw Assembled Lockwasher 30105494 5305-01-130-6100589 Screw Assembled Lockwasher 3010590 5305-01-119-8621590 Screw Assembled Lockwasher 3010596 5305-01-088-6019591 Screw Assembled Lockwasher 3010592 5305-01-176-8018592 Screw Assembled Lockwasher 3010597 5305-01-086-7036593 Screw Assembled Washer 425567 5305-00-042-5597594 Seal 67946 5365-00-197-9327595 Seal 3900216 5310-01-188-0997

TM 9-2320-272-24-4


D-20

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


596 Seal 8265 5310-00-246-0221

597 Seal 186780 5330-00-864-5422

598 Seal 188318 5330-01-301-1761

599 Seal 145530 5330-01-201-3623

600 Seal 3902466 5330-01-272-1246

601 Seal 7059240 5330-00-414-3754

602 Seal 3909410 5330-01-192-2037

603 Seal 3903475 5330-01-791-8047

604 Seal 032579 5330-01-143-4186

605 Seal 11607302-7 5330-00-340-3637

606 Seal 10937693-3 2510-01-197-4200

607 Seal 17657/55-542465 5330-01-150-9691

608 Seal 10875107-7 5330-01-119-5801

609 Seal 7409940 5330-00-292-1600610 Seal 500207 5330-00-585-3210611 Seal E-450121VG 5330-01-131-5416612 Seal 3003156 5330-01-072-8830613 Seal 3915707 5340-01-281-7792614 Seal 8735035 5330-00-470-2115615 Seal 8735034 5330-00-419-9468616 Seal 87350536 5330-00-419-9469617 Seal 10608E44S 5330-00-020-5375618 Seal 10937640 5330-00-338-0774619 Seal 10915159 9390-00-405-0215620 Seal 7373291-3 5330-00-152-3217621 Seal 10937691 5330-01-098-6555622 Seal 10937727 5330-01-016-1245623 Seal 12302744 5330-01-209-7354624 Seal 500163 5330-00-178-2191625 Seal S-1003-A 5365-00-598-5255626 Seal 23010610 2840-01-141-9503627 Seal 1205-Y-1633 5330-01-137-4799628 Seal C-366005 2590-01-134-9834629 Seal A-1205-D-2162 5330-01-308-0175

TM 9-2320-272-24-4


D-21

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


630 Seal A-1205-N-2120 5330-01-272-1147

631 Seal 11607267-2 9320-00-421-7230

632 Seal 10937683-2 9390-00-158-2408

633 Seal 8380420 9320-00-451-8080

634 Seal Assembly 12375801 5330-00-740-9550

635 Seal Assembly 3033677,3071085

5330-00-005-0407

636 Seal Ring 6880389 5330-01-141-9579

637 Seal Ring 6830187 2520-00-405-1842

638 Seal Ring 23014632 2520-00-557-6211

639 Seal Ring 6839163 5330-00-374-4873

640 Seal Ring 23017696 2520-01-130-5770641 Seal Ring MS28775-111 5330-00-579-8108642 Seal Ring 032570 5330-01-135-4067643 Seal Ring 035552 5330-01-135-4808644 Seal Washer 3918191 5310-01-340-8469645 Seal Washer 3903037 5310-01-195-1441646 Seal Washer 3914896 5310-01-331-9411647 Seal-Locking Retainer 3909063 5310-01-143-0542648 Self-Locking Screw 940937 5305-00-292-4594649 Self-Locking Screw MS35764-1297 5306-01-052-2402650 Self-Locking Screw 9409225 5305-00-638-2362651 Shim 68192 5365-00-378-2885652 Shim 12256738-1 5365-01-110-8183653 Side Cover Gasket 7346899 5330-00-734-6899654 Sleeve C5165X4 4730-00-969-6941655 Sleeve 8120115B,

120115B4730-00-054-2571

656 Sleeve 8 12011B657 Sleeve Bearing 7346983 3120-00-537-0614658 Slotted Nut 7979183 5310-00-740-9621659 Snapring N5002-500MD 5325-00-914-5837660 Snapring S-16255 2815-00-815-0355661 Snapring 1229-H-2816 5325-01-162-7624

TM 9-2320-272-24-4


D-22

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


662 Snapring 112302 5325-00-420-9696

663 Snapring 1229-U-2829 5325-01-129-6849

664 Snapring 378391 5325-00-477-0304

665 Snapring MS90707-1050 5325-00-419-3322

666 Soft Ball Bearing 213769 3110-01-079-8190

667 Speed Nut 17-10015-13 5310-00-885-7734

668 Spring 68274 5360-00-664-5343

669 Spring Center Nut MS51968-14 5310-00-732-0560

670 Spring Center Nut 10883157 5305-00-139-7074

671 Spring Guide 23045085 4710-00-557-5885

672 Spring Nut 7951891 5310-01-122-2060673 Spring Nut 5305-18 5310-01-122-2060

674 Spring Nut MS13532-35 5315-00-814-3530675 Springtite Assembly 1164243 5306-00-238-5661676 Steering Knuckle Boot

Replacement Kit5704510 2530-01-25-9272

677 Steering Parts Kit 1790522K 2530-01-339-7913678 Steering Parts Kits 5223281 2530-01-340-0365679 Stop Screw 5225875 5306-00-281-1651680 Suction Flange Gasket 67963 5330-00-171-7267681 Terminal MS20659-127 5940-00-113-3147682 Thrust Ring Set 157280683 Thrust Washer 31P-27 5310-00-469-4039684 Tiedown Strap MS3367-1-0 5975-00-984-6582685 Tiedown Strap MS3367-3-9 5975-00-451-5001686 Tiedown Strap MS3367-2-0 5975-00-899-4606687 Tiedown Strap MS3367-1-9,

SST2SC5975-00-074-2072

688 Tiedown Strap MS3367-6-9 5975-00-133-8696689 Tiedown Strap 12256372 5340-01-104-9012690 Tiedown Strap MS3367-7-9 5975-00-570-9598691 Tiedown Strap MS3367-1-9 5975-01-013-2742692 Tiedown Strap MS3367-4 5975-00-727-5153693 Tiedown Strap 11669079-5 4730-01-331-6630

TM 9-2320-272-24-4


D-23

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


694 Tiedown Strap MS3367-5-9 5975-00-111-3208

695 Tiedown Strap MS2367-202

696 Tiedown Strap MS3367-2-9 5975-00-156-3253

697 Tiedown Strap MS3367-3-0 5975-00-985-6630

698 Top Cover Gasket 7535079 5330-00-138-8388

699 Transmission Oil Filter 6883044 2520-01-124-6469

700 Turbocharger Repair Kit 3802149 2950-01-271-2345

701 Two-Piece Seal 032791A1 2530-01-131-7445

702 Universal Joint Kit CP85WB62 2520-01-280-4129

703 Universal Joint Parts Kit 5704528 2520-00-460-6477

704 Universal Plate 7335053 5340-01-119-5682705 Valve Guide Pin 6834410 2520-01-011-1068

706 Valve Repair Kit 289352 2530-01-134-1834707 Valve Repair Kit 17BV361 4820-01-034-0971708 Valve Seat Inseat 170296 5340-00-933-3009709 Valve Spring 6836928 5360-01-123-5483710 Vent Door Weatherseal 7373317 9390-00-737-3317711 Washer 3902425 5310-01-209-0508712 Washer 3906659 5310-01-270-8417713 Washer 6834908 5310-00-557-5942714 Washer 11511514 5310-01-286-5452715 Washer 65003-S 5310-01-099-2550716 Washer 3901798 5310-01-270-8388717 Wear Sleeve Kit 99293 4910-01-313-4621718 Weatherseal 12368265 9390-01-285-9623719 Wiper 7409553 2590-00-740-9553720 Wiper Strip 2012993-4 5330-00-972-2635721 Wood 11682324-1722 Wood 11682324-2723 Wood 11682323-1724 Wood 11682323-2725 Wood 11665738 2510-01-180-6164726 Woodruff Key MS35756-8 5315-00-616-5526727 Woodruff Key MS35756-6 5315-00-616-5514-

TM 9-2320-272-24-4


D-24

(1)

ITEMNO

(2)

NOMENCLATURE

(3)

PARTNUMBER

(6)


728 Woodruff Key MS35756-14 5315-00-616-5520

729 Woodruff Key MS35756-17 5315-00-012-4553

730 Woodruff Key MS20067-270 5315-00-042-3293

731 Woodruff Key MS35756-13 5315-00-616-5521

732 Woodruff Key MS35756-1 5315-00-616-5519

733 Woodruff Key MS35756-38 5315-00-043-1789

734 Woodruff Key 8328341 5315-00-281-7651

735 Woodruff Key MS35756-21 5315-00-616-5500

736 Woodruff Key MS35156-20 5315-00-616-5501

737 Woodruff Key M20067-493 5315-01-119-5239

738 Woodruff Key 9300-1 5315-00-276-4438

TM 9-2320-272-24-4

APPENDIX E

COMMON AND SPECIAL TOOL IDENTIFICATION LIST

E - l . S C O P E

This appendix list common and special tools outside of the general mechanic’s toolkit which you will needwhen servicing M939 series vehicles.

E-2. EXPLANATION OF COLUMNS

a. Column (1) - Item Number. This number is assigned to each entry in the listing and is referencedin the Initial Setup of applicable task under the heading of special tools, test equipment, or tools.

b. Column (2) - Item Name. Name or identification of special or common tool.

c. Column (3) - National Stock Number. This identifies the manufacturer’s part number or catalognumber assigned to each tool or kit.

d. Column (4) - Part Number. This is the National Stock Number assigned to each tool or kit; use itto request or requisition the tool or kit.

e. Column (5) - Reference. This is the supply catalog number in which the common tool can be found.Special tools are not found in supply catalogs and are referenced individually in the reference column.

E-1

TM 9-2320-272-24-4

COMMON AND SPECIAL TOOL IDENTIFICATION LIST (Contd)

E-2

(1)

REFERENCECODE NO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


(5)

REFERENCE

1 General's Mechanic Tool Kit SC5180-90CL-N26 5180-00-177-70332 Adapters J-24459 5120-01-054-4045

3 Adjusting Wrench 3375165 4910-01-097-6927

4 Air Gauge Assembly 20511320 5220-01-298-5730

5 Air Seal Installer 20511263 5120-01-285-7620

6 Angle Cutter, 60 GGG-C-613 5133-00-228-2323 4940-95-CL-BO2

7 Ball Joint Vise 1160002854 4910-00-999-1506 Special Tool

8 Barring Tool ST-747 4910-00-150-5798 Special Tool

9 Bead Cutting Tool ST-788 5110-00-932-2089 Special Tool

10 Bearing Installer J-25393A 5120-01-132-5448 Special Tool

11 Bearing Installer, Front Support J-24457 5120-01-141-9459 Special Tool12 Bearing Punch 20511262 5120-01-285-5192

13 Bearing Replacer 7950082 5120-00-795-0082 Special Tool

14 Bearing Replacer 7950159 5120-00-795-0159 Special Tool15 Bearing Replacer J-28435 5120-01-134-844916 Belt Tension Gauge ST-1136 5220-01-141-577617 Bolt Inserter Tool J-35198 4910-01-220-151218 Boring Tool, Oil Pump 3375206 4910-01-085-782419 Brake Reliner MILR 13495TYCR1 4910-00-173-5310 4910-95-CL-A3120 Brake Repair Pliers J-33111 5120-01-152-231821 Brakeshoe Adjusting Tool J-34061 5120-01-154-302922 Burnishing Tool ST-708 4910-00-999-1503 Special Tool23 Bushing Installer 3005319 5120-00-792-161224 Bushing Installer, Center

SupportJ-24794 5120-01-132-5470 Special Tool

25 Bushing Replacer J-36376 5120-01-132-546926 Cam Busing Replacement Tool ST-782 5120-00-953-966427 Center Support Lifter J-24455 5120-01-054-4001 Special Tool28 Cleaning Brush ST-876 7920-00-168-3244 Special Tool29 Compressor Bar and Screw J-24475 5120-01-132-5449 Special Tool30 Compressor Base J-24475-A 5120-01-132-5449 Special Tool31 Compressor, Low and First

SpringJ-24452 5120-01-054-7221 Special Tool

32 Compressor, Piston Ring ST-755 5120-00-116-7676 Special Tool33 Crosshead Guide Spacer ST-633 4910-00-150-5797

TM 9-2320-272-24-4


E-3

(1)

REFERENCECODE NO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


(5)

REFERENCE

34 Cutter Seat ST-662 4910-00-999-1208

35 Cylinder Liner Clamps 3822503 5120-01-262-7309

36 Dial Indicator 196A 5120-00-277-8840 4910-95-CL-A63

37 Driver Handle J-24202-4 5120-01-054-4042 Special Tool

38 Driver Handle J-8092 5120-00-677-2259 Special Tool

39 Dust Shield Installer J-24198 5120-01-054-4052 Special Tool

40 Electrical Tool Kit 7550526 5180-00-876-9336 4910-95-CL-A31

41 Engine and Transmission Sling J-36130-812 4910-01-353-2519 Special Tool

42 Engine Barring Tool 3377321 5120-01-262-7307

43 Engine Barring Tool 3377371 5120-02-285-5193

44 Engine Repair Stand 3375193 4910-00-977-7506

45 First Clutch Clearance Gauge J-26914 5210-01-065-9030 Special Tool

46 Forward Clutch ClearanceGauge

J-29146 5210-01-134-8224

47 Fourth Clutch Clearance Gauge J-29156 5120-01-134-8225 Special Tool48 Front Support Lifter J-24473 5120-01-054-4056 Special Tool49 Fuel Injecion Tester

(Test Stand)11020200 4910-00-817-7431

50 Fuel Pump Test Stand DFP 156 4910-01-194-766751 Gauge, Hydraulic Pressure 3005456 4910-00-792-8304 Special Tool52 Gauge Block ST-547 5210-01-157-309153 Gauge, Injector Protrusion 3376220 5210-00-690-7949 Special Tool54 Gauge, Keystone J-24599 5220-01-028-110955 Gauge, Mechanical Force 5210-01-018-2832 4910-95-CL-A3156 Gauge, Wheel Alignment

Toe-In/OutWA361 5210-00-529-1205 4910-95-CL-A74

57 Gear Pump Block Plate ST-844 5365-00-904-215958 Gear Unit Lifter J-24454 5120-01-054-4057 Special Tool59 Guide Pin J-1927-1 5120-01-144-4483 Special Tool60 Guide Pin J-24315-1 5315-01-141-945861 Handle 7010321 5120-00-601-2234 Special Tool62 Heat Gun 500A 4940-00-561-100263 Holding Fixture J-23642 5120-01-132-546864 Holding Fixture Adapter Set J-24462 5120-01-054-4043 Special Tool65 Holding Fixture Base J-3289-20 5120-01-144-4484

TM 9-2320-272-24-4


E-4

(1)

REFERENCECODE NO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


(5)

REFERENCE

66 Indicator, Level and Angle 3375855 4910-00-074-0020

67 Injection Sleeve Extractor ST-1140 4910-00-150-5858 Special Tool

68 Injector Leakage Detector 3375375 5120-01-029-6861 Special Tool

69 Injector and Valve AdjustmentKit

3375842 4910-00-548-7984 Special Tool

70 Injector Body Wrench ST-1298 5120-00-033-2738

71 Injector Nozzle Tester 7551255 4910-00-255-8641

72 Injector Sleeve Cutter ST-884 4910-00-981-3105 Special Tool

73 Injector Sleeve ExpanderTool/Cutter

ST-880 3441-00-922-6699 Special Tool

74 Injector Sleeve Holding Tool ST-1179 5120-00-104-1795

75 Injector Sleeve InstallationMandrel/Driver

ST-1227 5120-00-981-3108 Special Tool

76 Injector Timing Fixture 3375522 4910-01-394-0391

77 Inner Wheel Socket 5120-00-378-4411 5120-00-378-4411 Special Tool

78 Liner Clamp Set 3376669 5120-00-104-1816

79 Liner Driver, EngineCylinder Sleeve

ST-1229 5120-00-999-1206 Special Tool

80 Micrometer Set, Outside, 0-6 in. GGG-C-105TYICLISTA

5210-00-554-7134 4910-95-CL-A63

81 Micrometer, Depth 445BS-6RL 5120-00-619-4045 4910-95-CL-A6382 Micrometer, Inside, 0-1 In. GGG-C-105 5210-00-221-191883 Micrometer, Inside, 2-12 In. 124B 5120-00-221-1921 4910-95-CL-A6384 Mounting Plate 11600040 4910-00-977-750585 Mounting Plate 3375133 4910-01-128-2685 Special Tool86 Multimeter AN/PSM-45 6625-01-139-2512 4910-95-CL-A7287 Nozzle Cleaning Kit 3376947 2915-01-285-252788 Oil Filter Wrench J-29927 5120-01-037-159589 Oil Primer Pump 1P0540 5120-01-217-9642 Special Tool90 Oil Pump Body Centering Band J-24461 5120-01-054-4044 Special Tool91 Output Shaft Oil Seal Installer J-24620 5120-01-132-5466 Special Tool92 Output Shaft Seal and

Dust Shield RemoverJ-24171 5120-01-048-2153 Special Tool

93 Output Shaft Seal andDust Shield Remover

J-29355 5120-01-135-1978 Special Tool

TM 9-2320-272-24-4


E-5

(1)

REFERENCECODE NO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


(5)

REFERENCE

94 Pin Remover J-28708 5120-01-176-3893 Special Tool

95 Piston Return SpringCompressor

J-6438-01 5120-01-132-5465

96 Piston Ring Expander ST-763 5120-00-150-7486 Special Tool

97 Piston Ring Groove Gauge ST-560 5210-00-999-1209

98 Plunger Lift Device 1-688-130-135 4910-01-338-6241

99 Portable Magnetic Tester ST-1166 6635-01-128-2676

100 Power Steering PressureGauge Kit

7010267 4910-00-627-7043 Special Tool

101 Puller Kit 1178 5120-00-313-9496 4910-95-CL-A72

102 Puller Kit, Mechanical GGG-P 781 5180-00-423-1596 4910-95-CL-A31

103 Puller Kit, Universal J-24420 5180-00-999-4053 Special Tool

104 Puller Screw 8366689 5120-00-836-6689 Special Tool

105 Puller Set, BearingConverter Turbine

J-26956 5120-01-134-2338

106 Puller, Crosshead Guide ST-1134 4910-00-150-5848107 Puller, Cylinder Liner 3376015 5120-01-143-2032108 Puller, Main Bearing Cap ST-1178 5120-01-141-5777109 Puller, Mechanical 3822786 5120-01-291-5769110 Puller, Mechanical CG60DB 5120-00-620-0020111 Puller, Side Plug KDEP-1056 5120-01-343-2585112 Rack Extension 9-681-233-100 5340-01-341-6572113 Rear Axle Oil Seal Wiper

Replacer7950136 5120-00-795-0136 Special Tool

114 Retainer Ring Depth Tool J-24453 5120-01-054-4050115 Ring Bearing Installer J-24447 5120-01-054-4054 Special Tool116 Rocker Lever Bushing Block

And MandrelST-691 3460-00-999-1210 Special Tool

117 Seal Retainer Remover andReplacer

Y-56205

118 Second Clutch Clearance Gauge J-26918 5210-01-132-5467 Special Tool119 Separation Tube KDEP-1052 4910-10-336-8204120 Shaft Installation Tool 3375204 4910-01-118-3747 Special Tool121 Slide Hammer 3376617 5120-01-187-3626122 Slide Hammer J-6125-1 5120-01-112-2165 Special Tool123 Snap Gauge A210605 5220-00-449-7013 4910-95-CL-A63

TM 9-2320-272-24-4


E-6

(1)

REFERENCECODE NO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


(5)

REFERENCE

124 Snapring Gauge J-24208-4 5120-01-116-5016 Special Tool

125 Snapring Gauge J-6843-01 5120-00-293-0186 4910-95-CL-A62

126 Soldering Torch Kit LP-999 3439-00-542-0531 4910-95-CL-A74

127 Spindle Bearing Sleeve Remover 7950127 5120-00-378-4301 Special Tool

128 Spindle Bearing Sleeve Replacer(Front Axle Oil Seal)

7950129 5120-00-795-0129 Special Tool

129 Spring CompressorMain Regulator and Lockup

J-24459 5120-01-054-4045 Special Tool

130 Spring Pack Adjusting Tool ST-984 4910-00-150-5805

131 Spring Tester J-22738-02 4940-01-138-8259

132 Spring Tester SPT 6635-00-641-7346 4910-95-CL-A63

133 Spring Tester 3375182 4910-01-142-4929

134 Tappet Holder KDEP-1068 5120-01-345-2586

135 Tappet Spring Compressor KDEP-1505 5120-01-341-6000

136 Telescoping Gauge Set GGG-G-17 5210-00-473-9350 4910-95-CL-A63

137 Test Kit MILT 13011B 4910-00-250-2423 Special Tool138 Tester, Injector Spray Angle 11600056 4910-00-999-1501 Special Tool139 Third Cluth Clearance Gauge J-26916 5210-01-141-9457 Special Tool140 Tool Driver ST-1122 4910-00-150-5843 Special Tool141 Torque Angle Gauge 3823878 5120-01-386-5992142 Torque Wrench ST-753-1 2815-00-972-9661 Special Tool143 Torque Wrench Adapter ST-669 5120-00-103-4987 Special Tool144 Torque Wrench, 1/2-In. Drive A-A-2411 5120-00-640-6364 4910-95-CL-A31145 Torque Wrench, 3/4 In. Drive TES18000A 5120-01-118-3679 4910-95-CL-A31146 Torque Wrench, 3/8-In Drive TE-12A 5120-00-230-6380 4910-95-CL-A31147 Transmission Jack 9037-20BM 4910-00-585-3622 4910-95-CL-A62148 Transmission Shift Lever

Seal InstallerJ-26282 5120-01-115-1161 Special Tool

149 Transmission Shift LeverSeal Remover

J-26401 5120-01-118-6264 Special Tool

150 Travel Template 3375355 4910-01-074-0020151 Tube Reducer 23622 4730-01-284-9086152 Vacuum Tester ST-1257 4910-01-144-3837153 Valve Guide Arbor ST-954 4910-00-150-5804154 Valve Guide Arbor (Mandrel Set) ST-663 3460-00-999-1173

TM 9-2320-272-24-4


E-7/(E-8 blank)

(1)

REFERENCECODE NO.

(2)

NOMENCLATURE

(3)

PARTNUMBER

(4)


(5)

REFERENCE

155 Valve Pin Remover J-24412-2 5120-01-048-3128 Special Tool

156 Valve Seat Insert Extractor ST-1279 5120-01-128-2679

157 Valve Seat Insert Staking Tool ST-1124 4910-00-150-5844 Special Tool

158 Valve Seat Insert Tool ST-257 4910-00-345-3708

159 Vernier Caliper, 0-6 In. GGG-C-111 5210-00-113-1548 4910-95-CL-A31

160 Wheel Assembly Tool J-35193 4910-01-218-4490 Special Tool

161 Wrench Box CXM 1519 5120-01-178-5351

162 Wrench, Cup Retainer ST-995 5120-00-155-7492 Special Tool

163 Wrench, Crowfoot GGG-C-1507 5120-00-184-8390 Special Tool

164 Wrench, Crowfoot Injector ST-1072 4910-00-185-8511 Special Tool

165 Wrench, Locknut 3375166 4910-01-097-6928

166 Wrench, Spanner 4C4734 5120-01-440-1710 1U6680

167 Wrench, Spanner 8747917 Special Tool

168 Gauge, Pressure PDSS-1P-210A-004169 Flowmeter, 2-30 GPM 701-030 6680-01-188-0289170 Flowmeter, 10-100 GPM 801-100

-

-

-

-

TM 9-2320-272-24-4

APPENDIX F

ILLUSTRATED LIST OF MANUFACTURED ITEMS

S e c t i o n I . I N T R O D U C T I O N

This appendix includes complete instructions for making items authorized to be manufactured orfabricated at Unit, Direct Support and General Support Maintenance levels.

All bulk materials needed to manufacture the item are listed by part number or specification number ina tabular list on the illustration.

Sect ion II . MANUFACTURED ITEMS PART NUMBER INDEX

MATERIALS

NSN

9510-00-042-1493

DESCRIPTION

Mild Tool Steel Bar

Figure F-l. Flange Puller Standoff.

NOTE:1. Dimensions shown are in inches with metric equivalent.2. All dimensions are +/- 0.30 in. (0.76 mm).

INSTRUCTIONS:Fabricate and finish per diagram above.

F-1

TM 9-2320-272-24-4

Sect ion II . MANUFACTURED ITEMS PART NUMBER INDEX (Contd)

DESCRIPTION

Screw

MATERIALS

NSN

5305-01-072-4270

Figure F-2. Guide Screw.NOTES:

1. Two guide screws are required.2. Fabricate from screw part number 177734 (NSN 5305-01-072-4270) or equivalent.

PROCEDURE:1. Remove head of screw at A.2. Cut slot in screw at B. Slot shall be large enough to accommodate screwdriver tip.

F-2

TM 9-2320-272-24-4

A P P E N D I X G

TORQUE LIMITS

This appendix provides general torque limits for screws used on M939, M939A1, and M939A2 vehicles.Special torque limits are indicated in the maintenance procedures for applicable components. The generaltorque limits given in this appendix shall be used when specific torque limits are not indicated in themaintenance procedure. These general torque limits cannot be applied to screws that retain rubbercomponents. The rubber components will be damaged before the correct torque limit is reached. If a specialtorque limit is not given in the maintenance instructions, tighten the screw or nut until it touches themetal bracket, then tighten it one more turn.

Table G-l lists dry torque limits. Dry torque limits are used on screws that do not have lubricantsapplied to the threads. Table G-2 lists wet torque limits. Wet torque limits are used on screws that havehigh-pressure lubricants applied to the threads. For metric fasteners, refer to table G-3 for torque limitrequirements.

a. Measure the diameter of the screw you areinstalling.

b. Count the number of threads per inch.

c..

d.

Under the heading SIZE, look down the left-hand column until you find the diameterof the screw you are installing (there willusually be two lines beginning with thesame size).In the second column under SIZE, find thenumber of threads per inch that matches thenumber of threads you counted in step b.

CAPSCREW HEAD MARKINGS

Manufacturer's marks mayvary. These are all SAEGrade 5 (3-line).

Metric screws are of threegrades: 8.8, 10.9, and 12.9.Grades & Manufacturer’s marksappear on the screw head.

e. To find the grade screw you are installing,match the markings on the head to thecorrect picture of CAPSCREW HEADMARKINGS on the torque table.

f. Look down the column under the picture youfound in step e. until you find the torquelimit (in lb-ft or N°m) for the diameter andthreads per inch of the screw.

G-1

TM 9-2320-272-24-4

Table G-1. Torque Limits for Dry Fasteners.


TORQUE

SIZE SAE GRADE SAE GRADE SAE GRADE SAE GRADEN0.1or2 N0. 5 NO. 6 or 7 N0. 8

DIA. THREADS DIA.

INCHES PER INCH MILLIMETERSPOUND NEWTON POUND NEWTON POUND NEWTON POUND NEWTON

FEET METERS FEET METERS FEET METERS FEET METERS

1/4 20 6.35

1/4 28 6.35

5/16 18 7.94

5/16 24 7.94

3/8 16 9.53

3/8 24 9.53

7/16 14 11.11

7/16 20 11.11

1/2 13 12.70

1/2 20 12.70

9/16 12 14.29

9/16 18 14.29

5/8 11 15.88

5/8 18 15.88

3/4 10 19.05

3/4 16 19.05

7/8 9 22.23

7/8 14 22.23

1 8 25.40

1 14 25.40

1-1/8 _____ 28.58

1-1/4 _______ 31.75

1-3/8 _______ 34.93

1-1/2 _______ 38.10

5 6.78

6 8.14

11 14.92

13 17.63

18 24.41

20 27.12

28 37.97

30 40.68

39 52.88

41 55.60

51 69.16

55 74.58

63 85.43

95 128.82

105 142.38

115 155.94

160 216.96

175 237.30

235 318.66

250 339.00________ _____

_____ ______

_____ _____

_ _ _ _ _ _ _ _

8 10.85

10 13.56

17 23.05

19 25.76

31 42.04

35 47.46

49 66.44

55 74.58

75 101.70

85 115.26

110 149.16

120 162.72

150 203.40

170 230.52

270 366.12

295 400.02

395 535.62

435 589.86

590 800.04

660 894.96

800. 1,084.8-880 1,193.3

______ _ _ _ _ _

1,460- 1,979.8.1,680 2,278.l

1,940- 2,630.6-2,200 2,983.2

10 13.56 12 16.27_ _ _ _ _ _ _ _ 14 18.98

19 25.76 24 32.54____ _ _ _ 27 36.61

34 46.10 44 59.66_ _ _ _ _ _ _ _ 49 66.44

55 74.58 70 94.92_ _ _ _ _ _ _ _ 78 105.77

85 115.26 105 142.38

_ _ _ _ _ _ _ 120 162.72

120 162.72 155 210.18_ _ _ _ _ _ _ 170 230.52

167 226.45 210 284.76_ _ _ _ _ _ _ 240 325.44

280 379.68 375 508.50

_ _ _ _ _ _ _ _ 420 569.52

440 596.64 605 820.38_ _ _ _ _ _ _ 675 915.30

660 894.96 910 1,233.96

_ _ _ _ _ _ _ _ 990 1,342.44_ _ _ _ _ _ _ _ 1,280- 1,735.68

1,440 1,952.64

_ _ _ _ _ _ _ _ 1,820 2467.922,000 2,712.00

_ _ _ _ _ _ _ _ 2,380- 3,227.282,720 3.688.32

_ _ _ _ _ _ _ _ 3,160- 4,284.963,560 4,827.36

G-2

TM 9-2320-272-24-4

Table G-2. Torque Limits for Wet Fasteners.


TORQUE

SIZE SAE GRADE SAE GRADE SAE GRADE SAE GRADENo.1 or 2 No .5 N0.6 or 7 No.8

DIA. THREADS DIA. POUND NEWTON POUND NEWTON POUND NEWTON POUND NEWTONINCHES PER INCH MILLIMETERS FEET METERS FEET METERS FEET METERS FEET METERS

1/4 20 6.35 4.5 6.1 7.2 9.76 9.0 12.20 10.8 14.64

1/4 28 6.35 5.4 7.32 9.0 12.20 _____ _____ 12.6 17.09

5/16 18 7.94 9.9 13.42 15.3 20.75 17.1 23.19 21.6 29.29

5/16 24 7.94 11.7 15.87 17.1 23.19 ____ _ _ _ _ 24.3 32.95

3/8 16 9.53 16.2 21.97 27.9 37.83 30.6 41.49 39.6 53.70

3/8 24 9.53 18.0 24.41 31.5 42.71 _ _ _ _ _ _ _ 44.1 59.80

7/16 14 11.11 25.2 34.17 44.1 59.80 49.5 67.12 63.0 85.43

7/16 20 11.11 27.0 36.61 49.5 67.12 _ _ _ _ _ _ 70.2 95.19

1/2 13 12.70 35.1 47.60 67.5 91.53 76.5 103.73 94.5 128.14

1/2 20 12.70 36.9 50.04 76.5 103.73 _ _ _ _ _ _ _ _ _ _ 108.0 146.45

9/16 12 14.29 45.9 62.24 99.0 134.24 108.0 146.45 139.5 189.16

9/16 18 14.29 49.5 67.12 108.0 146.45 ____ _ _ _ _ _ 153.0 207.47

5/8 11 15.88 56.7 76.89 135.0 183.06 150.3 203.81 189.0 256.28

5/8 18 15.88 85.5 115.94 153.0 207.47 _____ _ _ _ _ _ 216.0 292.90

3/4 10 19.05 94.5 128.14 243.0 329.51 252.0 341.71 337.5 457.65

3/4 16 19.05 103.5 140.35 265.5 360.02 _____ _ _ _ _ _ _ 378.0 512.57

7/8 9 22.23 144.0 195.26 355.5 482.06 396.0 536.98 544.5 738.34

7/8 14 22.23 157.5 213.57 391.5 530.87 _____ _ _ _ _ _ 607.5 823.77

1 8 25.40 211.5 286.79 531.0 720.04 594.0 805.46 819.0 1,110.56

1 14 25.40 225.0 305.10 594.0 805.46 _____ _____ 891.0 1,208.20

1-1/8 _ _ _ _ 28.58 _ _ _ _ _ _ _ _ _ _ 720.0- 976.32- _ _ _ _ _ _ _ _ _ _ 1,152.0- 1,562.11-792.0 1,073.95 1,296.0 1,757.38

1-1/4 _ _ _ _ 31.75 _ _ _ _ ___________ _____ _____ ____ 1,637.99- 2,221.11-

1,800.00 2,440.80

1-3/8 _ _ _ _ 34.93 _____ _ _ _ _ _ 1,314.0- 1,781.78- _ _ _ _ _ _ _ _ 2,142.0. 2,904.55-1,512.0 2,050.27 2,448.0 3,319.49

1-1/2 _ _ _ _ 38.10 _ _ _ _ _ _ _ _ _ _ 1,746.0. 2,367.58- _ _ _ _ _ _ _ _ 2,844.0. 3,856.461,980.0 2,684.88 3,204.0 4,344.62

G-3

TM 9-2320-272-24-4

Table G-3.. Torque Limits for Metric Fasteners.


SIZE

M6

M8

M10

M12

M14

M16

M20

M24

M30

M36

POUNDFEET

7-11

21 - 35

45 - 65

80-120

130-190

200-280

400-520

700-900

1,400 - 1,800

2,400 - 3,000

TORQUE

NEWTONMETERS

9.49 - 14.92

28.48-47.46

61.02 - 88.14

108.48 - 162.72

176.28 - 257.64

271.20 - 379.68

542.40 - 705.12

949.20 - 1,220.40

1,898.40 - 2,440.80

3.254.40 - 4,068.OO

G-4

TM 9-2320-272-24-4

A P P E N D I X G ( C o n t d )

Tubing Application Tightening Assembly Instructions.

Slide tubing over barbed insert until it bottoms onfitting.

1. Slide nut and sleeve on tubing.2. Slide I.D. of tubing onto fitting insert until it

bottoms.3. Assemble nut to fitting body.

4. Tighten assembly finger-tight to cover bodythreads.

1.2.

3.

4.

Slide nut and sleeve on tubing.Slide I.D. of tubing onto fitting insert until itbottoms.

Assemble nut to fitting body.

Finger-tighten nut. From that point, tightenwith a wrench two complete turns.

1. Cut tubing to desired length. Ensure ends arecut reasonably square.

2. Slide tubing into preassembled fitting andpush until tube bottoms.

3. Tighten nut as indicated in chart. Anothercheck on proper assembly is dimension A,when nut is fully tightened.

DISASSEMBLY - Remove nut and pull tubingout of fitting body. Insert will remain on tubing.REASSEMBLY - Push tubing and insert intofitting body until it bottoms. Thread nut ontofitting body and tighten as in step 3.

TUBE O.D. TIGHTEN NUT TO: A1/4 85 - 115 lb-in. (9.6 - 13.0 N°m) .085/.1053/8 12 - 17 lb-ft (16.3 - 23.1 N°m) .125/.1451/2 25 - 33 lb-ft (33.9 - 44.7 N°m) .100/.1205/8 26 - 35 lb-ft (35.3 - 47.5 N°m) .115/.1353/4 38 - 50 lb-ft (51.5 - 67.8 N°m) .180/.200

G-5

TM 9-2320-272-24-4


Tubing Application Tightening Assembly Instructions (Contd).

1. Slide nut and sleeve on tubing. Threaded endof nut (1) must face out.

2. Insert tubing into fitting. Ensure tubing isbottomed on fitting shoulder.

3. Thread nut onto fitting body until it is handtight.

4. From that point, tighten with a wrench thenumber of turns indicated at right.

Some tasks require the use of a torque wrench adapter when the nut or screw cannot be reached witha regular socket on the end of the torque wrench. These adapters add to the overall length of the torquewrench and make the dial or scale reading less than the actual torque applied to the nut or screw. Toprevent overtorquing and damage to equipment, calculate correct dial or scale reading using ConversionFormula (para. G-5).

G-6

TM 9-2320-272-24-4


Corrected dial or scale readings are determined by the use of the following formula:

Corrected =reading

Requiredt o r q u e v a l u e +

Length of torque wrench + Length of adapterLength of torque wrench

NOTE

The length of the torque wrench ismeasured from the center of the handleto the center of the drive. The length ofthe adapter is measured from the centerof the drive to the center of the wrench.

In this example, the torque wrench measures 22 in. (55.9 cm) and the adapter is 3 in. (7.6 cm). Therequired torque is 19 lb-ft (25.8 N°m).

Corrected = 19 lb-ft (25.8 N•m) +22 in. (55.9 cm) + 3 in. (7.6 cm)

reading 22 in. (55.9 cm)

C o r r e c t e d = 19 lb-ft (25.8 N•m) +25 in. (63.5 cm)

reading 22 in. (55.9 cm)

Corrected =reading

19 lb-ft (25.8 N•m) + 1.14

Corrected =reading

17 lb-ft (23.1 N•m)

G-7/(G-8 blank)

TM 9-2320-272-24-4

A P P E N D I X H

S C H E M A T I C A N D W I R I N G D I A G R A M S

Foldout 1.Foldout 2.Foldout 3.Foldout 4.Foldout 5.Foldout 6.

Foldout 7.

Foldout 8.

Foldout 9.Foldout 10.

M939/A1 Electrical System Wiring DiagramM939A2 Electrical System Wiring Diagram (1 of 2)M939A2 Electrical System Wiring Diagram (2 of 2)M939/A1 Cab Air System DiagramM939/A1 Air Supply Line DiagramM939/A1 Air Control Line Diagram

M939/A1 Air Vent Line DiagramM939A2 Schematic Diagram for M939 Expansible Van

M939A2 CTIS Electrical/Pneumatic DiagramM939A2 Air Supply Line to CTIS Diagram

H-3H-5H-7H-9

H-11H-13

H-15

H-17

H-19H-21

H-1 /(H-2 blank)

TM 9-2320-272-24-4

Para Page

INDEX

Para Page

A

100-amp alternator harnessreplacement:

Installation.. ....................... 3-427b 3- 1098Removal.. ............................ 3-427a 3- 1096

100-amp alternatorreplacement:

Installation.. ....................... 3-426b 3-1094Removal.............................. 3-426a 3-1094

100-amp voltage regulatorreplacement:

Installation ......................... 3.428b 3-1100Removal .............................. 3-428a 3-1100

3-phase receptacle wiringharness replacement:

Installation.. ....................... 5-100b 5-604Removal.. ............................ 5-100a 5-604

400 Hz converter harnessconduit replacement:


400 Hz converter replacement:Installation.. ....................... 4-169b 4-804Removal.. ............................ 4-169a 4-804

400 Hz supply wiring harnessreplacement:

Installation.. ....................... 5-96b 5-592Removal .............................. 5-96a 5-590

A-frame kit maintenance:Inspection.. ......................... 3-414b 3-1048Installation.. ....................... 3-414c 3-1048Removal .............................. 3-414a 3-1046

Accelerator linkage (M939/A1)maintenance:

Adjustment.. ....................... 3-42c 3-124Installation.. ....................... 3-42b 3-124Removal.. ............................ 3-42a 3-124

Accelerator linkage (M939A2)maintenance:

Adjustment.. ....................... 3-43f 3- 128Assembly ............................ 3-43d 3-128Cleaning and inspection...... 3-43c 3-128Disassembly.. ..................... 3-43b 3-126Installation.. ....................... 3-43e 3-128Removal.. ............................ 3-43a 3-126

Accelerator pedal, bracket, rod,and stopscrew replacement:


Access door, bonnet,maintenance:

Assembly ............................ 5-86d 5-550Cleaning and inspection...... 5-86c 5-550Disassembly.. ..................... 5-86b 5-550Installation.. ....................... 5-86e 5-552Removal .............................. 5-86a 5-549

Access step, spare tire carrier,cargo, replacement:


Access step, spare tire carrier,dump and tractor,replacement:


Accessory drive and pulley,engine, maintenance:

Accessory drive assembly .... 4-26e 4-190Accessory drive cleaning and

inspection ......................... 4-26d 4-188Accessory drive

disassembly.. .................... 4-26c 4-188Accessory drive installation. 4-27f 4-190Accessory drive pulley

installation.. ..................... 4-26g 4-192Accessory drive pulley

r e m o v a l .................... ......... 4-26a 4-186Accessory drive removal.. .... 4-26b 4-186

Actuator, front brake, repair:Adjustable actuator

assembly .......................... 4-112e 4-598Adjustable actuatordisassembly.. ..................... 4-112a 4-596

Cleaning and inspection ...... 4-112c 4-596Stationary actuator

assembly .......................... 4-112d 4-598Stationary actuator

disassembly.. .................... 4-112b 4-596Actuator, rear brake, repair:

Assembly ............................ 4-113c 4-602Cleaning and inspection...... 4-113b 4-600Disassembly.. ..................... 4-113a 4-600

Adapter housing and firstclutch piston maintenance:

Assembly.. .......................... 5-57d 5-380Cleaning and inspection ...... 5-57c 5-380Disassembly.. ..................... 5-57b 5-378Removal.. ............................ 5-57a 5-378

Adapter housing, low clutch,low planetary carrier, andrear cover installation:

Installation.. ....................... 5-58 5-382

Index 1

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Adjustment, bearing, wheel:Front wheel bearingadjustment.. ....................... 3-225a 3-648Rear wheel bearingadjustment.. ....................... 3-225b 3-650

Air Fuel Control (AFC) fuelpump filter replacement:


Aftercooler and tubes(M939A2) replacement:


Air cleaner assembly andmounting bracketmaintenance:

Inspection.. ......................... 3-15b 3-52Installation.. ....................... 3-15c 3-54Removal.. ............................. ..3-15a 3-52

Air cleaner hose (M939A2)maintenance:

Assembly.. .......................... 3-13d 3-48Disassembly.. ..................... 3-13b 3-48Inspection.. ......................... 3-13c 3-48Installation.. ....................... 3-13e 3-49Removal.. ............................ 3-13a 3-48

Air cleaner indicator and tubemaintenance:

Cleaning and inspection...... 3-12c 3-44Installation.. ....................... 3-12d 3-46Removal.. ............................ 3-12b 3-44Testing.. ............................. 3-12a 3-42

Air cleaner intake pipe(M939/A1) maintenance:

Inspection.. ......................... 3-14b 3-50Installation.. ....................... 3-14c 3-50Removal.. ............................ 3-14a 3-50

Air compressor (M939/A1)maintenance:

Assembly ............................ 4-31e 4-226Cleaning.. ........................... 4-31c 4-220Disassembly.. ..................... 4-31b 4-218Inspection and repair.. ........ 4-31d 4-220Installation and timing....... 4 .31 f 4 -232Removal.. ............................ 4-31a 4-214

Air compressor (M939A2)maintenance:

Assembly.. .......................... 4-52c 4-322Cleaning and inspection...... 4-52b 4-318Disassembly.. ..................... 4-52a 4-314

Air compressor and lines(M939A2) replacement:


Air compressor coolant lines(M939A2) replacement:

Cleaning and inspection...... 3-57b 3-168Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-57c 3-168Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57a 3-168

Air compressor coolant supplyand return tubes (M939/A1)maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55c 3-161Return tube installation . . . . . 3-55e 3-163Return tube removal . . . . . . . . . . . 3-55b 3- 161Supply tube installation . . . . . 3-55d 3-162Supply tube removal . . . . . . . . . . . 3-55a 3-160

Air conditioner drain tubereplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-382b 3-938Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-382a 3-938

Air conditioner manual starterswitches replacement:


Air conditioner replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-88b 5-564Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88a 5-563

Air couplings replacement:Front air couplings

Installation . . . . . . . . . . . . . . . . . . . . . . . 3-208d 3-590Front air couplings removal 3-208a 3-584Rear air couplings

installation (M923/A1/A21 3-208e 3-592Rear air couplings removal

(M923/A1/A2) . . . . . . . . . . . . . . . . . . . 3-208b 3-586Rear air couplings

installation (M929/A1/A2,M931/A1A2, M934/A1/A2,M936/A1/A2) . . . . . . . . . . . . . . . . . . . . 3-208f 3-594

Rear air couplings removal(M929/A1/A2,M931/A1/A2,M9341/A1/A2,M936/A1/A2) . . . . . . . . . . . . . . . . . . . . 3-208c 3-588

Air cylinder, transfer caseinterlock, replacement:


Air dryer and check valvemaintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-464d 3-1272Cleaning and inspection...... 3-464c 3-1272Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-464b 3-1272Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-464e 3-1274Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-464a 3-1270

Air dryer filter replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-465b 3-1276Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-465a 3-1276

Index 2

TM 9-2320-272-24-4

INDEX

Para Page

Air dryer kit (M923/A1/A2,M9251/A1/A2, M927/A1/A2,M928/A1/A2, M934/A1/A2)replacement:


Air dryer kit (M929/A1/A2,M930/A1/A2, M931/A1/A2,M932/A1/A2, M936/A1/A2)replacement:


Air Fuel Control (AFC) tube(M939A2) maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18b 3-61Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-18c 3-61Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18a 3-61

Air gauge replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-87b 3-252Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87a 3-252

Air governor maintenance:Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-207d 3-582Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-207b 3-580Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-207a 3-580Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-207c 3-582

Air lines, fabrication . . . . . . . . . . . . . . . 3-452 3-1232Air manifold tee, brake

chamber, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-189b 3-520Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189a 3-520

Air manifold, rear axle,maintenance:


Air reservoir (supply tank),primary, replacement:


Air reservoir (supply tank),secondary, replacement:


Air reservoir drainvalvesreplacement:


Air reservoir one-way checkvalve replacement:


Air reservoir, emergency springbrake (supply tank),replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-204b 3-570Removal .............................. 3-204a 3-570

(Contd)

Para Page

Air seals, hub, leak test:Front hub leak test . . . . . . . . . . . . . 3-462a 3-1264Rear hub leak test . . . . . . . . . . . . . . 3-462b 3-1266

Air vent control assembly,fresh, replacement:


Airbrake hand control valve(M931/A1/A2, M932/A1/A2)trailer, replacement:


Alcohol evaporatorreplacement:

Installation ,........................ 3-211b 3-600Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-211a 3-600

Alternator and mountingbracket (M939/A1)replacement:


Alternator drivebelts(M939/A1) maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78b 3-222Installation and

adjustment . . . . . . . . . . . . . . ......... 3-78c 3-222Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78a 3-222

Alternator pulley (M939/A1)replacement:


Alternator, 100-amp,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-426b 3-1094Removal . . . ........................... 3-426a 3-1094

Alternator, mounting bracket,and pulley (M939A2)maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-80e 3-230Alternator and mounting

bracket installation . . . . . . . . . . 3-80d 3-230Alternator and mounting

bracket removal . . . . . . . . . . . . . . . . 3-80a 3-228Pulley installation . . . . . . . . . . . . . . 3-80c 3-230Pulley removal . . . . . . . . . . . . . . . . . . . . 3-80b 3-229

Amber warning lightreplacement:


Anchor post, toggle clamp,replacement:


Index 3

TM 9-2320-272-24-4

Para

Appendix A, references:Field manuals . . . . . . . . . . . . . . . . . . . . A-4Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3Other publications . . . . . . . . . . . . . . A-7Publications index . . . . . . . . . . . . .. A-2Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1Technical bulletins . . . . . . . . . . . . . . A-6Technical manuals . . . . . . . . . . . . . . A-5

Appendix B, MaintenanceAllocation Chart (MAC):

Explanation of columnsin remarks, section IV . . . . . . . B-5

Explanation of columnsin the MAC, section II . . . . . . . B-3

Explanation of columnsin tool and test equipmentrequirements,section III . . . . . . . . . . . . . . . . . . . . . . . . . B-4

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Maintenance functions . . . . . . . . B-2

Appendix C,expendable/durable suppliesand materials list:

Explanation of columns . . . . . . . C-1Scope . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . C-1

Appendix D, mandatoryreplacement parts:

Explanation of columns . . . . . . . D-2Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-l

Appendix E, common andspecial tool identification list:

Explanation of columns... . . . . E-2Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Appendix F, illustrated list ofmanufactured items . . . . . . . . . . . . . . F- 1

Appendix G, torque limits:General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1How to use torque table...... G-3Torque limits . . . . . . . . . . . . . . . . . . . . . . G-2

Appendix H, schematic andwiring diagrams . . . . . . . . . . . . . . . . . . . . H1

Approach plates, fifth wheel,replacement:

INDEX

Page

A-2A-1A-4A-1A-1A-3A-2

B-3

B-2

B-3B-1B-1

C-1C-1

D-lD-l

E-1E-1

F-1

G-1G-1G-1

H-1


Arm, pitman, replacement(Ross):


Arm, pitman, replacement(Sheppard):


(Contd)

Para Page

Arm, roller, dump,maintenance:

Assembly.. .......................... 5- 104d 5-613Disassembly ....................... 5-104b 5-612Inspection and repair.. ........ 5-104c 5-612Installation.. ....................... 5-104e 5-613Removal.. ............................ 5-104a 5-612

Army documents,shipment of.. ......................... 6-7 6-2

Army Petroleum, Oils, andLubricants (POL). ................. 1-8 1-2

Assembly, PMCS .................... 2-18 2-58Assist cylinder, steering,

replacement:Assembly.. .......................... 3-233c 3-664Disassembly ....................... 3-233b 3-664Installation.. ....................... 3-233d 3-666Removal.. ............................ 3-233a 3-662Travel adjustment.. ............ 3-233e 3-666

Atmospheric fuel tank ventsystem kit replacement:

Installation.. ....................... 3-44lb 3- 1141Removal.. ............................ 3-441a 3-1140

Atomizer (M939/A1), ether,replacement:


Atomizer and temperaturesensor (M939A2), ether,replacement:

Installation.. ....................... 3-38b 3- 118Removal.. ............................ 3-38a 3- 118

Automatic brake (hoist winch)adjustment:

Adjustment.. ....................... 3-383 3-940Automatic throttle kit

(M936/A1) replacement:Installation.. ....................... 3-440b 3-1136Removal.. ............................ 3-440a 3-1134

Auxiliary outlet socket andreceptacle (M936/A1/A2)replacement:


Axle breather, front and rear,replacement:


Axle carrier differential, frontand rear, maintenance:

Cleaning and inspection ...... 4-100b 4-564Installation.. ....................... 4-100c 4-565Removal.. ............................ 4-100a 4-564

Index 4

Axle engagement air cylinder,transfer case, front,replacement:

Installation.. .......................Removal ..............................

Axle leakage test:Corrective action .................Test.. ..................................

Axle seal, front, replacement:Installation.. .......................Removal ..............................

Axle shaft, rear, maintenance:Inspection ...........................Installation.. .......................Removal ..............................

Axle, forward-rear and rear-rear, replacement:

Installation.. .......................Removal..............................

Axle, front, replacement:Installation.. .......................Removal ..............................

INDEX (Contd)

Para Page

TM 9-2320-272-24-4

Para Page

4-84b 4-5084-84a 4-508

4-106b 4-5824-106a 4-582

3-160b 3-4393-160a 3-439

3-157b 3-4333-157c 3-4333-157a 3-433

4-101b 4-5704-101a 4-566

4-99b 4-5604-99a 4-558

B

Backrest cushion, companionseat cushion, frame, and,replacement:


Backrest cushion, driver’s seatcushion, frame and,replacement:


Baffles, seals, and plates,radiator, replacement:


Battery box cover replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-123b 3-332Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123a 3-332

Battery box heater pad, enginecoolant, replacement:


Battery box replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-128b 3-342Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128a 3-342

Battery cable and terminaladapter replacement:


Battery ground cablemaintenance:

Connection.. ........................ 3-126b 3-338Disconnection ...................... 3-126a 3-338

Battery maintenance:Inspection and cleaning.. .... 3-125b 3-336Installation.. ....................... 3-125c 3-337Removal.. ............................ 3-125a 3-336

Beam rollers, retractable,replacement:

End roller installation....... .. 5-69d 5-476End roller removal .............. 5-69c 5-476Support roller installation... 5-69b 5-474Support roller removal.. ...... 5-69a 5-474

Beam, retractable beam driveshaft and lock, maintenance:

Cleaning, inspection,and repair.. ....................... 5-68b 5-472

Installation.. ....................... 5-68c 5-472Removal.. ............................ 5-68a 5-470

Beam, retractable,replacement:


Bearing adjustment, wheel:Front wheel bearingadjustment.. ....................... 3-225a 3-648Rear wheel bearingadjustment.. ....................... 3-225b 3-650

Bearing sleeve, spindle,replacement:


Bearings, crankshaft and main,maintenance:

Cleaning and inspection ...... 5-8b 5-50End play clearance.. ............ 5-8d 5-56Installation.. ....................... 5-8c 5-52Removal.. ............................ 5-8a 5-48

Blackout and clearance lightswiring harness replacement:


Blackout and emergency lightfixtures replacement:


Blackout bypass wiringharness maintenance:

Installation.. ....................... 5-93c 5-580Removal.. ............................ 5-93a 5-580Repair.. ............................... 5-93b 5-580

Index 5

TM 9-2320-272-24-4

Blackout circuit plungers,hinged roof-operated,replacement:

Para

INDEX

Page


Blackout light maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117c 3-308Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-117b 3-308Installation. . . . . . . . . . . . . . . . . . . . . . . . . 3-117d 3-308Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117a 3-308

Blackout light switch and110-volt receptaclereplacement:


Blackout light switch, side andrear door maintenance:


Blackout panel, windowreplacement:


Block, cylinder liners and,maintenance:

Cleaning and inspection...... 5-7cCylinder liners installation. 5-7dDisassembly . . . . . . . . . . . . . . . . . . . . . . . 5-7bRemoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7a

Block, cylinder liners and,maintenance:

5-385-465-365-34

Cylinder liner and engineblock cleaning andinspection . . . . . . . . . . . . . . . . . . . . . . . . . 5-28d 5-190

Cylinder liner inspection . . . . . 5-28a 5-184Cylinder liner installation... 5-28f 5-194Cylinder liner removal . . . . . . . . . 5-28b 5-186Engine block assembly . . . . . . . . 5-28e 5-192Engine block disassembly.. . 5-28c 5-188

Body assembly, cargo,maintenance:

Cleaning and inspection...... 4-142b 4-718Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-142d 4-718Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142a 4-716Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142c 4-718

Body, dump, maintenance:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-144c 4-728Inspection and repair . . . . . . . . . . 4-144b 4-727Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144a 4-726

Body, van, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-66b 5-466Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66a 5-464

Body, wrecker, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-152b 4-750Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152a 4-748

Index 6

(Contd)

Para Page

Bonnet access doormaintenance:

Assembly.. .......................... 5-86d 5-550Cleaning and inspection...... 5-86c 5-550Disassembly.. ..................... 5-86b 5-550Installation.. ....................... 5-86e 5-552Removal.. ............................ 5-86a 5-549

Bonnet door maintenance:Assembly.. .......................... 5-87d 5-560Cleaning and inspection...... 5-87c 5-558Disassembly.. ..................... 5-87b 5-556Installation.. ....................... 5-87e 5-562Removal.. ............................ 5-87a 5-554

Bonnet frame partsreplacement:


Bonnet handle and control rodreplacement:


Boom elevating cylinderpacking replacement:

Installation. ........................ 5-103b 5-610Removal.. ............................ 5-103a 5-610

Boom elevating cylinder repair:Assembly.. .......................... 5-102c 5-608Cleaning, inspection,

and repair.. ....................... 5-102b 5-608Disassembly.. ..................... 5-102a 5-606

Boom elevating cylinderreplacement:


Boom extension cylinder repair:Assembly. ........................... 5-106c 5-628Cleaning, inspection,

and repair.. ....................... 5-10b 5-628Disassembly ....................... 5-106a 5-626

Boom extension cylinderreplacement:


Boom floodlight wirereplacement:


Boom repair and adjustment:Assembly.. .......................... 4-204c 4-952Cleaning, inspection,

and repair.. ....................... 4-204b 4-950Disassembly.. ..................... 4-204a 4-950Vertical adjustment.. .......... 4-204d 4-953

Boom replacement:Installation.. ....................... 4-194b 4-914Removal.. ............................ 4-194a 4-912

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Boom roller maintenance:Assembly ............................ 4-197d 4-924Cleaning and inspection...... 4-197c 4-924Disassembly.. ..................... 4-197b 4-922Installation.. ....................... 4-197e 4-924Removal.............................. 4-197a 4-922

Boom, inner, replacement:Installation.. ....................... 4-195b 4-918Removal.............................. 4-195a 4-916

Boot, steering knuckle,maintenance:

Cleaning and inspection...... 3-155b 3-430Installation.. ....................... 3-155c 3-430Removal.. ............................ 3-155a 3-430

Bows, cargo body cover,replacement:


Box, battery, replacement:Installation.. ....................... 3-128b 3-342Removal.. ............................ 3-128a 3-342

Box, electrical junction,replacement:


Box, electrical load center,maintenance:

Assembly ............................ 4-161c 4-782Disassembly.. ..................... 4-161b 4-782Installation.. ....................... 4-161d 4-784Removal.. ............................ 4-161a 4-776

Box, electrical, maintenance:Inspection ........................... 4-162b 4-790Installation.. ....................... 4-162c 4-790Removal.............................. 4-162a 4-790

Brace, dump safety,installation:


Bracket (M939/A1), personnelfuel burning heater mounting,replacement:

Installation.. ....................... 4-216b 4- 1006Removal .............................. 4-216a 4-1006

Bracket (M939A2), personnelfuel burning heater andmounting, replacement:


Bracket (M939A2), surge tankand, replacement:


Bracket, fuel can, replacement:Installation.. ....................... 4-187b 4-896Removal.. ............................ 4-187a 4-896

Para Page

Bracket, hood crossmember,maintenance:


Bracket, parking brake cableand, replacement:


Bracket, rod, and stopscrew,accelerator pedal,replacement:


Bracket, steering gear (Ross),and, replacement:


Bracket, steering gear(Sheppard), and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-118b 4-620Removala............................. 4-118a 4-618

Bracket, wet air reservoir(supply tank) and,replacement:


Brackets (M939A2), upperradiator hoses and,replacement:


Brackets, engine lifting,replacement:


Brake chamber, air manifoldtee, replacement:


Brake chamber, combinationspring (emergency) andservice, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-182b 3-506Removal . . . . . . . . . . . . . . ............... 3-182a 3-506

Brake chamber, service,replacement:


Brake chamber, spring(emergency), maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193c 3-528Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-193a 3-528Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193b 3-528

Index 7

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Brake lever and switch,parking, replacement:


Brake mechanism checks andadjustments (front and rear):

Brakeshoe check andadjustment . . . . . . . . . . . . . . . . . . . . . . . 3-179a 3-498

Checking brakeshoe wear ... 3-179b 3-500Mechanism inspection . . . . . . . . . 3-179c 3-500

Brake modification kit(M939A2), engine exhaustbrake, replacement:


Brake modification kit(M939A2), engine exhaustbrake, replacement:


Brake pedal (treadle) valve(M936/A1/A2) replacement:


Brake pedal (treadle) valverepair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108c 4-586Cleaning and inspection...... 4-108b 4-586Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-108a 4-584

Brake pedal (treadle) valvereplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-197b 3-538Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197a 3-536

Brake pedal maintenance:Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-196c 3-534Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-196b 3-534Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196a 3-534

Brake proportioning valvereplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-199b 3-546Removal. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 3-199a 3-546

Brake spider, front,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-183b 3-508Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-183a 3-508

Brake spider, rear,replacement:


Brake valve, spring parking,replacement:


Brake valve, spring,maintenance:

Adjustment.. .......................Installation.. .......................Removal..............................

Brake, (hoist winch),automatic, adjustment:

Adjustment .........................Brake, parking, adjustment:

Lever arm adjustment.. ......Major adjustment.. .............Minor adjustment.. .............Test ....................................

Brakedrum dustcover, parking,replacement:


Brakedrum, parking andservice, repair:

Cleaning .............................Inspection.. .........................

Brakeshoe replacement:Installation.. .......................Removal..............................

Brakeshoe, parking andservice, repair:

Inspection.. .........................Parking brakeshoe

assembly ..........................Parking brakeshoe

disassembly.. ....................Service brakeshoe

assembly ..........................Service brakeshoe

disassembly.. ....................Brakeshoes, parking,

replacement:Installation.. .......................Removal ..............................

Branched 400 hz receptaclewiring harness replacement:


Breather, axle, front and rear,replacement:


Breather, transmissionreplacement:


Brushguard, radiator,maintenance:

Inspection and repair..........Installation.. .......................Removal ..............................

3-173b 3-4823-173c 3-4823-173a 3-482

3-383 3-940

3-172d 3-4803-172c 3-4803-172b 3-4783-172a 3-478

3-177b 3-4943-177a 3-494

4-110a 4-5924-110b 4-592

3-180b 3-5023-180a 3-501

4-111c 4-595

4-111e 4-595

4-111a 4-594

4-ll ld 4-595

4-ll lb 4-594

3-176b 3-4923-176a 3-490

5-97b 5-5965-97a 5-596

3-159b 3-4383-159a 3-438

3-136b 3-3723-136a 3-372

4-136b 4-7024-136c 4-7044-136a 4-700

Index 8

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Brushguard, window,replacement:


Bumper, front spring,replacement:


Bumper, hood, replacement:Installation.. .......................Removal ..............................

Bumper, rear spring,replacement:


Bumperette replacement:Installation.. .......................Removal..............................

Bumpers, ladder rack,replacement:


Bumpers, rubber, side panel,replacement:


Bumpers, tailgate,replacement:


Bushing, ether thermal closevalve and, replacement:

Installation.. .......................Removal.. ............................

Bushing, front spring,maintenance:

Inspection ...........................Installation.. .......................Removal ..............................

Bushing, transmission mount,replacement:


Bypass tubing, fuel drain(M939/A1) and, replacement:


3-355b 3-8933-355a 3-893

3-164b 3-4503-164a 3-450

3-274b 3-7413-274a 3-741

3-165b 3-4513-165a 3-451

3-246b 3-6943-246a 3-694

3-366b 3-9073-366a 3-907

3-367b 3-9083-367a 3-908

3-261b 3-7213-261a 3-721

3-36b 3-1163-36a 3-116

3-163a 3-4483-163c 3-4483-163b 3-448

4-77b 4-4924-77a 4-492

3-17b 3-583-17a 3 -56

C

Cab cowl vent screen and doorreplacement:


Cab door catch replacement:Installation.. ....................... 3-321b 3-821Removal.............................. 3-321a 3-821

Cab door check rodreplacement:

Installation ......................... 3-318b 3-817Removal.. ............................ 3-318a 3-817

Cab door dovetail replacement:Installation.. ....................... 3-310b 3-809Removal.. ............................ 3-310a 3-809

Cab door dovetail wedgereplacement:


Cab door glass maintenance:Adjustment.. ....................... 3-314c 3-813Installation.. ....................... 3-314b 3-813Removal .............................. 3-314a 3-813

Cab door glass repair:Assembly ............................ 4-137b 4-706Disassembly.. ..................... 4-137a 4-706

Cab door hinge replacement:Installation.. ....................... 3-320b 3-820Removal .............................. 3-320a 3-820

Cab door inspection hole coverreplacement:


Cab door lock replacement:Installation.. ....................... 3-313b 3-812Removal.. ............................ 3-313a 3-812

Cab door regulator assemblyreplacement:


Cab door replacement:Installation.. ....................... 3-319b 3-318Removal.. ............................ 3-319a 3-818

Cab door weathersealreplacement:


Cab grab handle replacement:Installation ......................... 3-288b 3-773Removal.. ............................ 3-288a 3-773

Cab heat and defrost airducting replacement:


Index 9

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Cab heat shield, rear exhaustpipe, support bracket and,maintenance:

Inspection.. ......................... 3-49b 3-142Installation.. ....................... 3-49c 3-142Removal .............................. 3-49a 3-142

Cab hood stop bracketreplacement:

Installation ......................... 3-273b 3-740Removal .............................. 3-273a 3-740

Cab insulation replacement:Installation.. ....................... 3-306b 3-804Removal .............................. 3-306a 3-804

Cab mount, rear, replacement:Installation.. ....................... 3-305b 3-802Removal.. ............................ 3-305a 3-802

Cab protector shield, dump,maintenance:

Inspection and repair.. ........ 4-146b 4-732Installation.. ....................... 4-146c 4-732Removal.. ............................ 4-146a 4-731

Cab top seal and retainerreplacement:


Cab turnbuttons and lashinghooks replacement:


Cab windshield hingeassembly replacement:


Cab windshield repair:Assembly.. .......................... 4-138b 4-708Disassembly.. ..................... 4-138a 4-708

Cab, mount, front,replacement:


Cable and bracket, parkingbrake, replacement:


Cable assembly (M939/A2),front lights, replacement:


Cable, hinged roof and floorcounterbalance, maintenance:

Cable adjustment.. ............. 3-356c 3-895Installation.. ....................... 3-356b 3-894Removal.. ............................ 3-356a 3-894

Cable, hoist, winch,replacement:

Para Page


Cable, transfer case PowerTakeoff (PTO) control,replacement:


Cable, transmissionmodulator, maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-145c 3-400Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-145b 3-400Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145a 3-398

Calibration, fuel pump set up

Checking and adjustinggovernor weight pressure . . 5-181 5-116

Checking and adjustingthrottle lever travel . . . . . . . . . . . 5- 18h 5- 114

Fuel pump run-in . . . . . . . . . . . . . . . . 5-18c 5-108Mounting pump to

test stand . . . . . . . . . . . . . . . . . . . . . . . . . 5-18b 5-106Shutdown and removal

from test stand . . . . . . . . . . . . . . . . . 5-18n 5-119Testing and adjusting

fuel pressure . . . . . . . . . . . . . . . . . . . . . 5-18j 5-116Testing and adjusting

governor fuel pressure....... 5-18k 5-116Testing and adjusting

idle speed (VS governoronly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18m 5-118

Testing and adjustingidle speed . . . . . . . . . . . . . . . . . . . . . . . . . 5-18g 5-112

Testing and adjustingpump main pressure . . . . . . . . . 5-18i 5-114

Testing and adjustingthrottle leakage . . . . . . . . . . . . . . . . 5-18f 5- 112

Testing governor cutoff........ 5-18e 5-110Testing pump seals for

leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18d 5-110Throttle shaft cover

removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18a 5-104Cam follower housing

maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19d 4-150Cleaning and inspection...... 4-19c 4-148Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-19b 4-146Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-19e 4-152Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19a 4-144

Index 10

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Camshaft and gearmaintenance:

Assembly ............................Check backlash.. .................Cleaning and inspection ......Disassembly.. .....................Installation.. .......................Removal ..............................

Camshaft and gearmaintenance:

Assembly.. ..........................Cleaning and inspection......Check backlash and

end play.. ..........................Disassembly.. .....................Installation.. .......................Removal ..............................

Capacitor, governor pipingmaintenance:

Inspection.. .........................Installation .........................Removal ..............................

Capacitor, transfer case,replacement:


Cargo body assemblymaintenance:

Cleaning and inspection......Installation.. .......................Removal ..............................Repair .................................

Cargo body frame rail sillmaintenance:

Fabrication.. .......................Inspection.. .........................Installation.. .......................Removal ..............................

Cargo spare tire carrier (M923,M925, M927, M928)replacement:


Cargo spare tire carrier(M923A1/A2,M925A1/A2,M927A1/A2, M928A1/A2)replacement:


Cargo spare tire carrier accessstep replacement:


5-9e 5-625-9a 5-585-9d 5-605-9c 5-605-9f 5-625-9b 5-58

5-27e 5-1805-27d 5-178

5-27a 5-1745-27c 5-1765-27f 5-1815-27b 5-176

3-135b 3-3663-135c 3-3683-135a 3-364

4-91b 4-5224-91a 4-522

4-142b 4-7184-142d 4-7184-142a 4-7164-142c 4-718

4-143c 4-7234-143b 4-7224-143d 4-7254-143a 4-722

3-258b 3-7163-258a 3-716

3-259b 3-7183-259a 3-718

3-260b 3-7203-260a 3-720

Cargo stowage boxreplacement:


Cargo tailgate replacement:Installation.. ....................... 3-343b 3-876Removal.. ............................ 3-343a 3-876

Cargo troop seat replacement:Installation.. ....................... 3-340b 3-870Removal.. ............................ 3-340a 3-870

Cargo upper and lower wheelsplash guard replacement:


Carrier differential top covergasket and side cover gasketreplacement:

Side cover gasketinstallation.. ..................... 3-158d 3-437

Side cover gasket removal.. 3-158c 3-437Top cover gasket

installation.. ..................... 3-158b 3-436Top cover gasket removal .... 3-158a 3-434

Ceiling air ducts replacement:Installation.. ....................... 5-81b 5-536Removal.. ............................ 5-81a 5-536

Ceiling and framemaintenance:


Ceiling deflector and registersreplacement:


Ceiling filler and side panelsreplacement:


Ceiling rear cover replacement:Installation.. ....................... 5-80b 5-534Removal.. ............................ 5-80a 5-534

Ceiling transition maintenance:Assembly.. .......................... 5-82c 5-540Disassembly.. ..................... 5-82b 5-538Installation.. ....................... 5-82d 5-540Removal.. ............................ 5-82a 5-538

Center support maintenance:Assembly.. .......................... 5-50d 5-344Cleaning and inspection ...... 5-50c 5-342Disassembly.. ..................... 5-50b 5-342Installation.. ....................... 5-50e 5-346Removal.. ............................ 5-50a 5-340

Central Tire Inflation System(CTIS) operation ................... 1-25 1-78

Index 11

TM 9-2320-272-24-4

Para

INDEX

Page

Central Tire Inflation System(CTIS) troubleshooting . . . . . . . . . . 2-25 2-267

Characteristics, capabilities,and features, equipment . . . . . . . 1-13 1-5

Check valve, air dryer and,maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-464d 3-1272Cleaning and inspection...... 3-464c 3-1272Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-464b 3-1272Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-464e 3-1274Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-464a 3-1270

Check valve, air reservoir one-way, replacement:


Checks, door, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-365b 3-906Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-365a 3-906

Chemical agent alarmmounting bracket kitreplacement:

Chemical alarm wiringharness installation . . . . . . . . . . 3-417d 3-1064

Chemical alarm wiringharness removal .............. 3-417a 3-1058

Detector and alarm bracketinstallation.. ..................... 3-417c 3-1062

Detector and alarm bracketremoval.. ........................... 3-417b 3-1060

Chock anchors, front and rearfield (M936/A1), replacement:


Circuit breaker harness andcircuit breaker maintenance:

Circuit breaker harnessinstallation.. ..................... 4-158e 4-770

Circuit breaker harnessremoval.. ........................... 4-158a 4-770

Circuit breakerinstallation.. ..................... 4-158d 4-770

Circuit breaker removal.. .... 4-158b 4-770Repair.. ............................... 4-158c 4-770

Circuit breaker replacement:Installation.. ....................... 3-105b 3-288Removal.. ............................ 3-105a 3-288

Clamp, ladder locking,replacement:


Cleaning, general.. .................. 2-14 2-54Cleaning, general preparation

of vehicle for shipment .......... 6-2 6-1

(Contd)

Para Page

Clevis, winch cable,replacement:


Clip, side locking pin retaining,replacement:


Cluster, instrument,maintenance:

Assembly.. .......................... 3-83c 3-242Disassembly.. ..................... 3-83b 3-242Installation.. ....................... 3-83d 3-244Removal.. ............................ 3-83a 3-238

Clutch (M939/A1), fan drive,maintenance:

Assembly.. .......................... 4-61c 4-364Cleaning and inspection ...... 4-61b 4-363Disassembly.. ..................... 4-61a 4-356Fan drive clutchoperation check. ................ 4-61d 4-368

Clutch (M939/A1), fan drive,replacement:


Clutch (M939A2), fan drive,maintenance:

Assembly.. .......................... 4-62c 4-374Cleaning and inspection ...... 4-62b 4-372Disassembly.. ..................... 4-62a 4-370

Clutch actuator (M939/A1), fandrive, maintenance:


Clutch, first, maintenance:Cleaning and inspection ...... 5-53b 5-358Establishing clearance ........ 5-53d 5-360Installation.. ....................... 5-53c 5-360Removal.. ............................ 5-53a 5-358

Clutch, forward, maintenance:Assembly ............................ 5-47d 5-328Cleaning and inspection ...... 5-47c 5-326Disassembly ....................... 5-47b 5-322Installation.. ....................... 5-47e 5-331Removal.. ............................ 5-47a 5-322

Clutch, fourth, maintenance:Assembly.. .......................... 5-48d 5-336Cleaning and inspection ...... 5-48c 5-334Disassembly.. ..................... 5-48b 5-332Installation.. ....................... 5-48e 5-336Removal.. ............................ 5-48a 5-332

Clutch, low planetary carrier,adapter housing, and rearcover, low, installation:

Installation.. ....................... 5-58 5-382

Index 12

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Clutch, low, removal and,clearance:

Cleaning and inspection...... 5-56b 5-374Establishing clearance ........ 5-56c 5-376Removal.. ............................ 5-56a 5-374

Clutch, second, maintenance:Cleaning and inspection ...... 5-52b 5-354Establishing clearance ........ 5-52d 5-356Installation.. ....................... 5-52c 5-356Removal.. ............................ 5-52a 5-354

Clutch, third, maintenance:Cleaning and inspection...... 5-49b 5-338Installation.. ....................... 5-49c 5-339Removal.. ............................ 5-49a 5-338

Combination spring(emergency) and service brakechamber replacement:


Companion seat cushion,backrest cushion, and framereplacement:


Compartment, map,replacement:


Compensator, manifoldpressure, maintenance:

Assembly.. .......................... 5 -33d 5-226Cleaning and inspection ...... 5-33c 5-226Installation.. ....................... 5-33e 5-226Disassembly ....................... 5-33b 5-224Removal.. ............................ 5-33a 5-224

Composite light and bracket,front and rear, replacement:

Composite light lampinstallation.. ..................... 3-118n 3-320

Composite light lampremoval.. ........................... 3-118m 3-320

Front composite lightinstallation.. ..................... 3-118b 3-311

Front composite lightremoval.. ........................... 3-118a 3-310

Installation (M923/A1/A2)... 3-118d 3-312Installation (M929/A1/A2)... 3-118h 3-314Installation (M931/A1/A2)... 3-118j 3-316Installation (M934/A1/A2)... 3-1181 3-318Installation (M936/A1/A2)... 3-118f 3-313Removal (M923/A1/A21....... 3-118c 3-312Removal (M929/A1/A2) ....... 3-118g 3-314Removal (M931/A1/A2) ....... 3-118i 3-316Removal (M934/A1/A2) ....... 3-118k 3-318Removal (M936/A1/A2) ....... 3-118e 3-313

Compressed air and brakesystem operation .................. 1-23 1-55

Compressed air and brakesystem troubleshooting.. ....... 2-23 2-177

Compressor, air, (M939/A1),maintenance:

Assembly.. .......................... 4-31e 4-226Cleaning.. ........................... 4-31c 4-220Disassembly.. ..................... 4-31b 4-218Inspection and repair .......... 4-31d 4-220Installation and timing....... 4-31f 4-232Removal.. ............................ 4-31a 4-214

Compressor, air, (M939A2),maintenance:


Conduit, electrical load center,replacement:


Contact, brush, horn,replacement:


Control box, personnel fuelburning heater, replacement:


Control box, protective,replacement:


Control cable, throttle,maintenance:


Control switch, floodlight,maintenance:

Assembly.. .......................... 3-120d 3-324Disassembly.. ..................... 3-120b 3-324Inspection.. ......................... 3-120c 3-324Installation.. ....................... 3-120e 3-325Removal .............................. 3-120a 3-324

Control system operation.. ...... 1-20 1-25Control Unit, Electronic (ECU),

replacement:Installation.. ....................... 3-468b 3-1282Removal.. ............................ 3-468a 3-1282

Control valve, front axleengagement, transfer case,replacement:


Index 13

TM 9-2320-272-24-4

INDEX (Contd)

Control valve, lock-in, transfercase front axle, replacement:

Installation. . . . . . . . . . . . . . . . . . . . .. .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Control valve, transmission,replacement:

Installation... . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . .. . . . . . . . . . . . . . . .

Control valve, washer,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . .. . . . . . . . . . . . . . . . . .

Control valve, windshieldwiper, replacement:

Installation . . . . . . . .. . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Controls, defrost and heat,replacement:

Installation . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Converter, 400 Hz,replacement:

Installation . . . .. . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light harness(M929/A1/A2, M930/A1/A2)replacement:

Installation . . . .. . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light harness(M934/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light mount(M929/A1/A2, M930/A1/A2)replacement:

Installation . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light mount(M934/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light mountreplacement:

Installation ............ . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning lightreplacement:

Installation . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light resistorand leads replacement:

Installation... . . . . . . . . . . .... . . . .Removal. . . . . . . . . . . . . . .. . . . . . . .

3-147b 3-4043-147a 3-404

5-44b 5-3065-44a 5-306

3-191b 3-5243-191a 3-524

3-192b 3-5263-192a 3-526

3-294b 3-7863-294a 3-786

4-169b 4-8044-169a 4-804

3-434b 3-11183-434a 3-1116

3-435b 3-11223-435a 3-1120

3-432b 3-11123-432a 3-1112

3-431b 3-11103-431a 3-1108

3-430b 3-11063-430a 3-1104

3-437b 3-11283-437a 3-1128

3-436b 3-11263-436a 3-1124

Para Page Para Page

Convoy warning light switchreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . 3-438b 3-1130Removal . . . . . . . . .. . . . . . . . . . . . . . . . . 3-438a 3-1130

Coolant hoses and lines(M939A2) replacement:

Installation . . . . .. . . . . . . . . . . . . . . . . 3-56b 3-166Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56a 3-164

Coolant hoses and tubes(M939/A1) replacement:

Radiator inlet hoses andtube installation . . . . . . . . . . . . . . . 3-54j 3-158

Radiator inlet hoses andtube removal... . . . . . . . . . . . . . . . 3-54a 3-154

Radiator outlet hoses andtee installation . . . . . . . . . . . . . . . . . 3-54g 3-156

Radiator outlet hoses andtee removal . . . . . . . . . . . . . . . . . . . 3-54d 3-156

Surge tank hose installation 3-54h 3-156Surge tank hose removal..... 3-54c 3-156Thermostat housing hose,

radiator bypass tube, andhose installation . . . . . . . . . . . . . . . 3-54i 3-158

Thermostat housing hose,radiator bypass tube, andhose removal . . . . . . . . . . . . . . . . . . . . . 3-54b 3-154

Transmission oil coolerhoses and tube installation 3-54f 3-156

Transmission oil coolerhoses and tube removal.... 3-54e 3-156

Coolant lines (M939A2), aircompressor, replacement:

Cleaning and inspection...... 3-57b 3-168Installation . . . . . . . . . . . . . . . . . . . . . 3-57c 3-168Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-57a 3-168

Coolant lines (M939A2),turbocharger and,replacement:

Installation . . . . . . .. . . . . . . . . . . . . . . 3-2 lb 3-70Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-21a 3-68

Coolant supply and returntubes (M939/A1), aircompressor, maintenance:

Inspection . . . . . . . . . .. . . . . . . . . . . . . 3-55c 3-161Return tube installation . . . . . 3-55e 3-163Return tube removal . . . . . . . . . . . 3-55b 3-161Supply tube installation . . . . . 3-55d 3-162Supply tube removal . . . . . . . . . . . 3-55a 3-160

Coolant, heater engine,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . 3-397b 3-974Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-397a 3-974

Cooling system maintenance. . . 4-59 4-352

Index 14

INDEX (Contd)

Para Page

Cooling system servicing:Cleaning and flushing

system . . . . . . . . . . . . . . . . . . . . . . . . 3-53c 3-150Depressurizing system........ 3-53a 3-150Draining system . . . . .. . . . . . . . . . . . 3-53b 3-150Filling system . . . . . . . . . . . . . . . . . . . 3-53d 3-152

Coupling hoses (M931/A1/A2,M932/A1/A2), emergency andtrailer, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . 3-209b 3-596Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-209a 3-596

Couplings, air, replacement:Front air couplings

installation . . . . . . . . . . . . . . . . . . 3-208d 3-590Front air couplings removal 3-208a 3-584Rear air couplings

installation (M923/A1/A2) 3-208e 3-592Rear air couplings removal

(M923/A1/A2) . . . . . . . . . . . . . . . . . . . 3-208b 3-586Rear air couplings

installation (M929/A1/A2,M931/A1/A2, M934/A1/A2,M936/A1/A2)................... 3-208f 3-594

Rear air couplings removal(M929/A1/A2,M931/A1/A2,M934/A1/A2,M936/A1/A2) . . . . . . . . . . . . . . . . . 3-208c 3-588

Cover (in-cab), engine access,replacement:

Installation . . . . . . . . . . . . . . . . . . . 4-140b 4-712Removal. . . . . . . . . . . . . . . . . . . . . . . 4-140a 4-712

Cover, battery box,replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-123b 3-332Removal . . . . . . . . . . . . . . . . . . . . . . 3-123a 3-332

Cover, cab door inspection hole,replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-312b 3-811Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-312a 3-811

Cover, ceiling rear,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 5-80b 5-534Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80a 5-534

Cover, crankshaft rear, sealand, replacement:

Installation . . . . . . . . . . . . . . . . . . . 4-17b 4-136Removal . . . . . . . . . . . . . . . . . . . . . . . 4-17a 4-136

Cover, engine access,replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-13b 4-124Removal .......................... 4-13a 4-124

TM 9-2320-272-24-4

Para Page

Cover, fuel filter and,maintenance:

Cleaning and inspection......Installation (M939/A1) ......Installation (M939A2)........Removal (M939/A1) ............Removal (M939A2).............

Cover, housing assembly,replacement:


Cover, kit, radiator,replacement:


Cover, R.Q.V. governor,maintenance:

Adjustment.. .......................Assembly.. ..........................Cleaning andinspection .........................

Disassembly.. .....................Installation.. .......................Removal., ............................

Cover, R.Q.V. governor,maintenance:

Adjustment.. .......................Assembly.. ..........................Cleaning and

inspection .........................Disassembly.. .....................Installation.. .......................Removal ..............................

Crane control valve repair:Assembly.. ..........................Cleaning, inspection,

and repair.. .......................Disassembly.. .....................

Crane control valvereplacement:


Crane hydraulic filtermaintenance:

Assembly.. ..........................Cleaning and inspection......Disassembly.. .....................Installation.. .......................Removal ..............................

Crane hydraulic swinger motorreplacement:


3-30c 3-1063-30d 3-1063-30e 3-1073-30b 3-1053-30a 3-104

3-333b 3-8523-333a 3-852

3-395b 3-9703-395a 3-970

5-34e 5-2305-34d 5-230

5-34c 5-2285-34b 5-2285-34f 5 -2305-34a 5-228

5-35f 5-2385-35d 5-234

5-35c 5-2345-35b 5-2345-35e 5-2365-35a 5-232

5-108c 5-640

5-108b 5-6405-108a 5-636

4-201b 4-9404-201a 4-938

3-391d 3-9623-391c 3-9623-391b 3-9603-391e 3-9623-39 la 3-960

4-199b 4-9344-199a 4-934

Index 15

TM 9-2320-272-24-4

INDEX

Para Page

Crane swinger gearcase repair:Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107c 5-634Cleaning, inspection,

and repair . . . . . . . . . . . . . . . . . . . . . . 5-107b 5-632Disassembly . . . . . . . .. . . . . . . . . . . . . . 5-107a 5-630

Crane swinger gearcasereplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . 4-200b 4-936Removal . . . . . . . . . . . .. . . . . . . . . . . . . . . 4-200a 4-936

Crane swivel valvemaintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . 4-198c 4-930Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-198b 4-928Wiring harness

connection . . . . . . . . . . .. . . . . . . . . . . 4-198d 4-932Wiring harness

disconnection . . . . . . . . . . . . . . . . . 4-198a 4-926Crane wiring harness

replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . 3-386b 3-950Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-386a 3-948

Crankcase breather and tubemaintenance:

Breather and tubeinstallation (M939/A1)...... 3-2e

Breather and tube removal(M939/A1) ......................... 3-2a

Breather tubainstallation (M939A2)....... 3-2d

Breather tube removal(M939A2) ......................... 3-2b

Cleaning and inspection...... 3-2cCrankshaft and gear

maintenance:Assembly.. .......................... 5-29eCheck end play ................... 5-29aCleaning and inspection...... 5-29dDisassembly.. ..................... 5-29cInstallation.. ....................... 5-29fRemoval.. ............................ 5-29b

Crankshaft and main bearingsmaintenance:

Cleaning and inspection ...... 5-8bEnd play clearance.. ............ 5-8dInstallation.. ....................... 5-8cRemoval.. ............................ 5-8a

Crankshaft rear cover and sealreplacement:

Installation. ........................ 4-17bRemoval.. ............................ 4-17a

Crankshaft vibration anddamper replacement:

Inspection.. ......................... 4-14cInstallation.. ....................... 4-14dRemoval.. ............................ 4-14bRunout and wobble check... 4-14a

Index 16

3-6

3-2

3-4

3-43-4

5-2025-1965-1995-1985-2025-197

5-505-565-525-48

4-1364-136

4-1284-1284-1264-126

(Contd)

Para Page

Cross tube replacement:Installation.. ....................... 4-104b 4-578Removal.. ............................ 4-104a 4-578

Cross-shaft, transfer case,replacement:


Crossheads, fuel crossoverconnectors and, replacement:

Inspection.. ......................... 4-30b 4-210Installation and

adjustment.. ..................... 4-30c 4-212Removal.. ............................ 4-30a 4-210

Crossmembers, torsion barsand, replacement:


CTIS wiring harnessreplacement:


Cylinder head repair(M939/A1):

Assembly.. .......................... 5-3d 5-14Cleaning.. ........................... 5-3b 5-6Disassembly.. ..................... 5-3a 5-2Inspection.. ......................... 5-3c 5-6

Cylinder head repair(M939A2):

Assembly.. .......................... 5-25e 5-164Cleaning.. ........................... 5-25b 5-160Disassembly.. ..................... 5-25a 5-158Inspection.. ......................... 5-25c 5-160Repair.. ............................... 5-25d 5-162

Cylinder head replacement:Installation.. ....................... 4-12b 4-122Removal .............................. 4-12a 4-120

Cylinder head, rocker levers,push rods, and, replacement:

Cylinder head installation.. 4-41c 4-286Cylinder head removal.. ...... 4-4 lb 4-282Rocker levers and push

rods installation.. ............. 4-41d 4-289Rocker levers and push

rods removal.. ................... 4-41a 4-280Cylinder liners and block

maintenance:Cleaning and inspection ...... 5-7c 5-38Cylinder liners installation. 5-7d 5-46Disassembly.. ..................... 5-7b 5-36Removal.. ............................ 5-7a 5-34

INDEX (Contd)

Para Page

Cylinder liners and blockmaintenance:

Cylinder liner and engineblock cleaning andinspection ......................... 5-28d 5-190

Cylinder liner inspection.. ... 5-28a 5-184Cylinder liner installation ... 5-28f 5-194Cylinder liner removal.. ....... 5-28b 5-186Engine block assembly.. ...... 5-288 5-192Engine block disassembly ... 5-28c 5-188

Cylinder packing, boomelevating, replacement:


Cylinder, boom elevating,repair:

Assembly.. .......................... 5-102c 5-608Cleaning, inspection,


Cylinder, boom elevating,replacement:


Cylinder, boom extension,repair:

Assembly ............................ 5-106c 5-628Cleaning, inspection,


Cylinder, boom extension,replacement:


Cylinder, dump hoist,maintenance:


Cylinder, power steering assist,repair:



Cylinder, steering assist,replacement:

Assembly.. .......................... 3-233c 3-664Disassembly.. ..................... 3-233b 3-664Installation.. ....................... 3-233d 3-666Removal .............................. 3-233a 3-662Travel adjustment .............. 3-233e 3-666

TM 9-2320-272-24-4

Para Page

D

Damper, crankshaft vibrationand, replacement:

Inspection ....................... 4-14c 4-128Installation . . . . .. . . . . . . . . . . . . .. 4-14d 4-128Removal . . . . . . . . . . . . . . . . . . . . . . 4-14b 4-126Runout and wobble check... 4-14a 4-126

Damper, vibration,maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . 4-42b 4-290Installation . . . . . . . . . . . . . . . . . . . . 4-42c 4-290Removal . . . . . . . . . . . . . . . . . . . . . . . 4-42a 4-290

Dash control valve, springbrake, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-195b 3-532Removal . . . . . . . . . . . . . . . . . . . . . . . 3-195a 3-532

Data plates, description of . . . . . . 1-17 1-24Data, equipment . . . . . . . . . . . . . . . . . 1-16 1-22Davit and pulley, swing, van,

replacement:Installation . . . . . . . . . . . . . . . . . . . . 3-265b 3-726Removal . . . . . . . . . . . . . . . . . . . . . . . 3-265a 3-726

Davit chain and wire rope, van,replacement:


Davit winch (M934A1/A21, van,replacement:


Deck plate, fifth wheel,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-251b 3-700Removal . . . . . . . . . . . . . . . . . . . . . . . 3-251a 3-700

Deck plate, forward,replacement:


Decontamination (M13)apparatus mounting bracketkit replacement:

Installation (M923/A1/A2,M925/A1/A2, M927/A1/A2,M928/A1/A2).................... 3-419h 3-1076

Installation (M929/A1/A2,M930/A1/A2, M931/A1/A2,M932/A1/A2) . . . . . . . . . . . . . . . 3-419b 3-1074

Installation (M934/A1/A2).. 3-419d 3-1074Installation (M936/A1/A2).. 3-419f 3-1076Removal (M923/A1/A2,

M925/A1/A2, M9271A1/A2,M928/A1/A2)................. 3-419g 3-1076

Index 17

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Removal (M929/A1/A2,M930/A1/A2, M931/A1/A2,M932/A1/A2). ................... 3-419a 3-1074

Removal (M934/A1/A2)....... 3-419c 3-1074Removal (M936/A1/A2)....... 3-419e 3-1076

Deepwater fording air pressurehose replacement:

Installation (M939/A1). ...... 4-227d 4-1038Installation (M939A2)........ 4-227c 4-1034Removal (M939/A1)............ 4-227a 4-1034Removal (M939A2)............. 4-227b 4-1036

Deepwater fording controlreplacement:


Deepwater fordingpressurization valvereplacement:

Installation (M939/A1)....... 4-226b 4-1032Installation (M939A2)........ 4-226c 4-1030Removal (M939/A1)............ 4-226a 4-1028Removal (M939A2)............. 4-226b 4-1030

Deepwater fording regulatorvalve replacement:


Deflector, ceiling and registers,replacement:


Defrost and heat controlsreplacement:


Description and data index,equipment.. .......................... 1-12 1-5

Description of data plates.. ..... 1-17 1-24Description of major

components, location and.. .... 1-14 1-16Destruction of Army materiel to

prevent enemy use.. .............. 1-3 1-2Differences between models .... 1-15 1-20Differential and differential

carrier repair:Assembly and

adjustment.. ..................... 5-64c 5-44Cleaning, inspection, andrepair.. .............................. 5-64b 5-439

Disassembly.. ..................... 5-64a 5-432Differential oil seal, front,


Differential oil seal, rear,replacement:


Differential, front and rear axlecarrier, maintenance:

Cleaning and inspection ......Installation.. .......................Removal.. ............................

Diode, transfer case transorb,replacement:


Dipstick, dipstick tube,transmission, maintenance:

Installation.. .......................Inspection.. .........................Removal ..............................

Direct and general supportmechanical troubleshooting

symptom index ...................Direct and general support

mechanical troubleshooting...Disassembly, general.. ............Diverter assembly


Door catch, cab, replacement:Installation.. .......................Removal ..............................

Door checks replacement:Installation.. .......................Removal ..............................

Door handle and lockreplacement:


Door handle, outside,replacement:


Door hinge and sealreplacement:


Door hinge, cab, replacement:Installation.. .......................Removal ..............................

Door regulator assembly, cab,replacement:


Para Page

4-103b 4-5764-103a 4-576

4-100b 4-5644-100c 4-5654-100a 4-564

4-92b 4-5244-92a 4-524

3-134c 3-3623-134b 3-3623-134a 3-362

4-2 4-2

4-1 4-12-17 2-58

3-295b 3-7883-295a 3-788

3-321b 3-8213-321a 3-821

3-365b 3-9063-365a 3-906

3-364b 3-9053-364a 3-905

3-307b 3-8063-307a 3-806

3-362b 3-9023-362a 3-902

3-320b 3-8203-320a 3-820

3-317b 3-8163-317a 3-816

Index 18

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Door, bonnet, maintenance:Assembly.. .......................... 5-87d 5-560Cleaning and inspection...... 5-87c 5-558Disassembly.. ..................... 5-87b 5-556Installation.. ....................... 5-87e 5-562Removal.. ............................ 5-87a 5-554

Door, cab, replacement:Installation.. ....................... 3-319b 3-318Removal.. ............................ 3-319a 3-818

Door, check rod, cab,replacement:


Door, rear, maintenance:Assembly.. .......................... 4-154d 4-758Cleaning and inspection...... 4-154c 4-758Disassembly.. ..................... 4-154b 4-756Installation.. ....................... 4-154e 4-760Removal.............................. 4-154a 4-756

Doors, side, maintenance:Assembly.. .......................... 5-70d 5-480Cleaning and inspection ...... 5-70c 5-480Disassembly.. ..................... 5-70b 5-480Installation.. ....................... 5-70e 5-482Removal.. ............................ 5-70a 5-478

Doublecheck valve No. 1replacement:


Doublecheck valve No. 2(M931/A1/A2, M932/A1/A2)replacement:

Installation.. ....................... 3-214b, 3-606Removal.. ............................ 3-214a 3-606

Doublecheck valve No. 2replacement:


Doublecheck valve No. 5(M931/A1/A2,M932/A1/A2)replacement:


Doublecheck valves No. 3,No. 4, and quick-release valvereplacement:

Installation.. ....................... 3-216b 3-612. Removal.. ............................ 3-216a 3-610

Dovetail wedge, cab door,replacement:


Dovetail, cab door,replacement:


Drag link replacement:Installation ......................... 3-229b 3-655Removal.. ............................ 3-229a 3-655

Drain kit, hydraulic reservoir,replacement:


Drain tube, air conditioner,replacement:


Drainvalves, air reservoir,replacement:


Drive flange, front axle,maintenance:


Drive gear and driven shaft,transfer case speedometer,replacement:


Drive, tachometer,maintenance:


Drivebelt (M939/A1), waterpump, maintenance:

Adjustment.. ....................... 3-67a 3-196Inspection.. ......................... 3-67c 3-198Installation.. ....................... 3-67d 3-198Removal.. ............................ 3-67b 3-198

Drivebelt and drivebelttensioner (M939A2), fan,replacement:


Drivebelt tensioner (M939A2),fan drivebelt and,replacement:

Installation.. ....................... 3-7 lb 3-206Removal.. ............................ 3-71a 3-206

Drivebelts (M939A1), fan,maintenance:


Index 19

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Drivebelts, alternator(M939/A1), maintenance:



Drivebelts, steering pump,maintenance (M939/A1):

Adjustment.. ....................... 3-230a 3-656Inspection.. ......................... 3-230c 3-656Installation.. ....................... 3-230d 3-657Removal.. ............................ 3-230a 3-656

Driver’s seat cushion, backrestcushion, and framereplacement:


Driver’s seat frame and basemaintenance:


Driver’s seat replacement:Installation.. ....................... 3-283b 3-762Removal.. ............................ 3-283a 3-762

Driveshaft (M939/A1),tachometer maintenance:


Driveshaft, speedometermaintenance:


Drum (M939/A1), front huband, maintenance:

Cleaning and inspection ...... 3-223b 3-640Installation.. ....................... 3-223d 3-640Lubrication.. ....................... 3-223c 3-640Removal.. ............................ 3-223a 3-638

Drum (M939/A1), rear huband, maintenance:

Cleaning and inspection ...... 3-224b 3-644Installation.. ....................... 3-224d 3-646Lubrication.. ....................... 3-224c 3-644Removal.. ............................ 3-224a 3-642

Ducting, cab heat and defrost,air, replacement:


Ducting, fresh air inlet,replacement:


Index 20

Para Page

Ducts, ceiling air, replacement:Installation.. ....................... 5-81b 5-536Removal.. ............................ 5-81a 5-536

Dump and tractor spare tirecarrier access stepreplacement:


Dump body hydraulic hosereplacement:


Dump body maintenance:Installation.. ....................... 4-144c 4-728Inspection and repair.. ........ 4-144b 4-727Removal.. ............................ 4-144a 4-726

Dump cab protector shieldmaintenance:


Dump hoist cylindermaintenance:

Assembly.. .......................... 5-105d 5-620Cleaning and inspection ...... 5-105c 5-618Disassembly.. ..................... 5-105b 5-616Installation.. ....................... 5-105e 5-623Removal.. ............................ 5-105a 5-614

Dump hydraulic pumpreplacement.. ........................ 4-150 4-748

Dump roller arm maintenance:Assembly.. .......................... 5-104d 5-613Disassembly ....................... 5-104b 5-612Inspection and repair.. ........ 5-104c 5-612Installation.. ....................... 5-104e 5-613Removal.. ............................ 5-104a 5-612

Dump safety braceinstallation:


Dump spare tire carrier (M929,M930) replacement:


Dump spare tire carrier(M929A1/A2, M930A1/A2)replacement:


Dump subframe replacement:Installation.. ....................... 4-149b 4-746Removal. ............................. 4-149a 4-742

Dump tailgate assemblyreplacement:


TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Dump tailgate control linkagereplacement:

Installation . . . . . .. . . . . . . . . . . . . . 3-349b 3-886Removal . . . . . . . . . . . . . . . . . . . . . 3-349a 3-884

Dustcover, parking brakedrum,replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-177b 3-494Removal . . . . . . . . . .. . . . . . . . . . . 3-177a 3-494

Dustcovers, wheel brakedrum,replacement:

Front wheel dustcoversinstallation . . . . . . . . . . . . . . . . . 3-178c 3-496

Front wheel dustcoversremoval . . . . . . . . . . . . . . . . . . . 3-178a 3-496

Rear wheel dustcoversinstallation.. . . . . . . . . . . . . . . . 3-178d 3-496

Rear wheel dustcoversremoval . . . . . . . .. . . . . . . . . . . 3-178b 3-496

E

Electric heater (10 kw) wiringharness replacement:

Installation . . . . . . . . . . . . . . . . . 5-92b 5-578Removal . . . . . .. . . . . . . . . . . . . 5-92a 5-578

Electrical box maintenance:Inspection . . . . . . . . . . . . . . . 4-162b 4-790Installation . . . . . . . . . . . . . . . . . . 4-162c 4-790Removal . . . . . . . . . . . . . . . . . . . 4-162a 4-790

Electrical gauges replacement:Installation . . . . . . .. . . . . . . . . . . 3-86b 3-250Removal . . . . . . . . . . . . . . . . . . . . 3-86a 3-250

Electrical junction boxreplacement:

Installation . . . . . . . . . . . . . . . . . . 4-163b 4-792Removal . . . . . . . . . . . . . . . . . . . . 4-163a 4-792

Electrical load center boxmaintenance:

Assembly . . . . . . . . . . . . . . . . . . 4-161c 4-782Disassembly . . . . . . . . . . . . . . . . 4-161b 4-782Installation . . . . . . .. . . . . . . . . . . 4-161d 4-784Removal . . . . . . . . . . . . . . . . . . . . 4-161a 4-776

Electrical load center conduitreplacement:

Installation . . . . . . . . . . . . . . . 4-170b 4-806Removal . . . . . . . . . . .. . . . . . . 4-170a 4-806

Electrical switchesreplacement:

Accessory switchesinstallation . . . . . . . . . . . . . . . 3-107b 3-292

Accessory switchesremoval . . . . . . . . . . . . . . . . . . 3-107a 3-292

Battery and starterswitch installation . . . . . . . . 3-107d 3-293

Battery and starterswitch removal . . . . . . . . . . . . 3-107c 3-292

Electrical system

Para Page

troubleshooting . . . . . . . . . . . . . . 2-22 2-92Electrical systems operation . . . 1-22 1-45Electronic Control Unit (ECU)

replacement:Installation . . . . . . . . . . . . .. . . 3-468b 3-1282Removal . . . . . . . . . . . .. . . . . . . 3-468a 3-1282

Emergency and trailer couplinghoses (M931/A1/A2,M932/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . 3-209b 3-596Removal . . . . . . . . . . . . . . . . . . 3-209a 3-596

Emergency lamp wiringharness replacement:

Installation . . . . . . . . . . . . . . 5-94b 5-584Removal . . . . . . . . .. . . . . . . 5-94a 5-582

Emergency spring brake(supply tank) air reservoirreplacement:

Installation . . . . . . . . . . . . . 3-204b 3-570Removal . . . . . . . . . .. . . . . . 3-204a 3-570

Emergency stop control cablemaintenance:

Inspection . . . . . . . . . . . . 3-44b 3-132Installation . . . . . . . . . . . . . 3-44c 3-132Removal . . . . . . . .. . . . . . . . . 3-44a 3-130

Emergency/blackout light lampand lens replacement:

Installation . . . . . . . . . . . . . . 3-372b 3-915Removal . . . . . . . . . . .. . . . . 3-372a 3-915

End panel, hinged,maintenance:

Assembly . . . . . . . . . . . . . . . 4-155d 4-764Cleaning and inspection...... 4-155c 4-763Disassembly . . . . . . . . . . . . . 4-155b 4-762Installation . . . . . . . . . . . . . . . . 4-155e 4-764Removal . . . . . . . . . . . . . . . . . . 4-155a 4-762

Engine access cover (in-cab)replacement:

Installation . . . . . . . . . . . . . . 4-140b 4-712Removal . . . . . . . . . . . . . . . . . 4-140a 4-712

Engine accessory drive andpulley maintenance:

Accessory drive assembly . . . . 4-26e 4-190Accessory drive cleaning and

inspection ... . . . . . . . .. . . . . . 4-26d 4-188Accessory drive

disassembly.. . . . . . . . . .. . . . 4-26c 4-188Accessory drive installation. 4-27f 4-190Accessory drive pulley

installation . . . . . . . . . . . . .. . . . 4-26g 4-192Accessory drive pulley

removal . . . . . . . . . . . . . . . . . . . . 4-26a 4-186Accessory drive removal . . . . . 4-26b 4-186

Index 21

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Engine air intake manifoldmaintenance:


Engine and containerreplacement:


Engine AOAP valvemaintenance:

Installation.. ....................... 3-10c 3-40

RemovalOil sampling.. ..................... 3-10a 3-38

................................. 3-10b 3-40Engine coolant battery box

heater pad replacement:Installation.. ....................... 3-404b 3-994Removal.. ............................ 3-404a 3-994

Engine coolant heater controlbox replacement:


Engine coolant heater harness(M939/A1) replacement:


Engine coolant heater harness(M939A2) replacement:


Engine coolant heater hosereplacement:


Engine coolant heater pumpreplacement:


Engine coolant heaterreplacement:


Engine coolant oil pan shroudand exhaust tubereplacement:


Engine exhaust brakemodification kit (M939/A1)replacement:


Engine exhaust brakemodification kit (M939A2)replacement:


Engine exhaust manifoldmaintenance:


Engine hood maintenance:Adjustment.. ....................... 3-275c 3-746Installation.. ....................... 3-275b 3-744Removal.. ............................ 3-275a 3-742

Engine injector timinginstructions:

Fuel injectors installation ... 4-32h 4-242Fuel injectors removal.. ....... 4-32d 4-238General instructions.. ......... 4-32e 4-238Injector timing.. .................. 4-32g 4-240Rocker lever housing covers

installation.. ..................... 4-32k 4-246Rocker lever housing covers

removal.. ........................... 4-32a 4-236Rocker lever housing and

push tubes removal .......... 4-32b 4-236Rocker lever housing and

push tubes installation ..... 4-32j 4-244Timing tool setup.. .............. 4-32f 4-240Valve crossheads

installation andadjustment.. ..................... 4-323 4-244

Valve crossheads removal ... 4-32c 4-238Engine lift eyes replacement:

Installation.. ....................... 4 - l l b 4-118Removal.. ............................ 4 - l l a 4-118

Engine lifting bracketsreplacement:


Engine mounting brackets andisolators replacement:


Engine mounting on repairstand:

Installation (M939/A1). ...... 4-9a 4-100Installation (M939A2). ....... 4-9b 4-106Removal (M9391A1). ........... 4-9d 4-110Removal (M939A2) ............. 4-9c 4-108

Engine oil cooler (M939A2)maintenance:


Index 22

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Engine oil cooler maintenance:Assembly ............................ 4-23dCleaning and inspection ...... 4-23cDisassembly.. ..................... 4-23bInstallation ......................... 4-23eRemoval.. ............................ 4-23a

Engine oil filter maintenance:Cleaning and inspection...... 3-5dDraining oil.. ....................... 3-5aFilter shell and bolt

assembly (M939/A1). ........ 3-5eFilter shell and bolt

disassembly (M939/A1). ... 3-5cOil filter installation.. ......... 3-5fOil filter removal ................. 3-5b

Engine oil pan maintenance:Assembly.. .......................... 4-22dCleaning and inspection ...... 4-22cDisassembly.. ..................... 4-22bInstallation.. ....................... 4-22eRemoval.. ............................ 4-22a

Engine oil pump repair:Assembly.. .......................... 5-11dCleaning and inspection ...... 5-11bDisassembly.. ..................... 5-11aRepair.. ............................... 5-11c

Engine oil pump replacement:Gear backlash test.. ........... 4-21aInstallation.. ....................... 4-21cRemoval.. ............................ 4-2 lb

Engine run-in test and idlespeed adjustment:

Engine run-in test.. ............. 4-54aIdle speed adjustment.. ...... 4-54b

Engine water manifoldmaintenance:

Assembly.. .......................... 4-27dCleaning and inspection...... 4-27cDisassembly.. ..................... 4-27bInstallation.. ....................... 4-27eRemoval.. ............................ 4-27a

Entrance receptacle 220V3-phase wiring harnessmaintenance:

Installation.. ....................... 4-159cRemoval.. ............................ 4-159aRepair.. ............................... 4-159b

Equipment characteristics,capabilities, and features.. ... 1-13

Equipment data.. ................... 1-16Equipment description and

data index ............................ 1-12Ether atomizer (M939/A1)

replacement:Installation.. ....................... 3-37bRemoval.. ............................ 3-37a

4-1764-1764-1744-1764-174

3-203-18

3-20

3-203-213-20

4-1704-1704-1704-1724-168

5-885-845-785-86

4-1644-1664-164

4-3284-328

4-1964-1964-1944-1964-194

4-7724-7724-772

1-51-22

1-5

3-1173-117

Ether atomizer andtemperature sensor (M939A2)replacement:

Installation . . . . . . . . . . . . . . . . 3-38b 3-118Removal . . . . . . . . . . . . . . . . . . 3-38a 3-118

Ether cylinder and valvereplacement:

Ether cylinder installation... 3-35d 3-115Ether cylinder removal . . .. . . 3-35a 3-114Ether valve installation . . . . 3-35c 3-115Ether valve removal . . . . . . . . 3-35b 3-114

Ether start fuel pressureswitch (M939/A1)replacement:


Ether start switchreplacement:

Installation . . . . . . . .. . . . . . . . . . 3-33b 3-112Removal . . . . . .. . . . . . . . . . . . . 3-33a 3-112

Ether thermal close valve andbushing replacement:

Installation . . . . . . . . . . . . . . . . . . 3-36b 3-116Removal . . . . . . . . . . . . . . . . . . . 3-36a 3-116

Ether tubing replacement:Installation. . . . . . . . . . . . . . . 3-39b 3-120Removal........................ 3-39a 3-120

Ether, atomizer (M939/A1),replacement:


Ether, atomizer andtemperature sensor(M939A2), replacement:


European mini-lighting kitreplacement:


Evaporator, alcohol,replacement:


Exhaust heat shield accessorykit replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-449b 3-1224Removal......................... 3-449a 3-1224

Exhaust manifold replacement:Installation . . . . . . . . . . . . . . . . . . . . . 4-50b 4-312Removal.......................... 4-50a 4-312

Exhaust manifold, engine,maintenance:

Installation........................ 4-25b 4-184Removal . . . . . . . . . . . . . . . . . . . . . . . 4-25a 4-184

Index 23

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Exhaust stack replacement:Installation . . . . . . . . . . . . . . . 3-48b 3-140Removal . . . . . . . . . . . . . . . . . . 3-48a 3-140

Expanding and retractingmechanism locksreplacement:

Installation . . . . . . . . . . . . . . . . . 3-378b 3-926Removal . . . . . . . . . . . . . . . . . 3-378a 3-926

Exterior side panelmaintenance:

Assembly . . . . . . . . . . . . . . . . . . 5-73c 5-494Cleaning and inspection...... 5-73b 5-494Disassembly . . . . . . . . . . . . . . 5-73a 5-490

F

Fabrication of air lines.. . . . . . . . 3-452 3-1232Failsafe warning module


Fan actuator (M939A2), fanclutch and, maintenance:

Cleaning and inspection...... 3-74b 3-212Installation.. ....................... 3-74c 3-213Removal .............................. 3-74a 3-212

Fan and fan shroud (M939A2)maintenance:


Fan blade, radiator,(M939/A1) replacement:


Fan clutch and fan actuator(M939A2) maintenance:

Cleaning and inspection...... 3-74b 3-212Installation.. ....................... 3-74c 3-213Removal.............................. 3-74a 3-212

Fan drive clutch (M939/A1)maintenance:

Assembly.. .......................... 4-61c 4-364Cleaning and inspection...... 4-61b 4-363Disassembly.. ..................... 4-61a 4-356Fan drive clutchoperation check ................. 4-61d 4-368

Fan drive clutch (M939/A1)replacement:


Fan drive clutch actuator(M939/A1) maintenance:


Fan drive clutch maintenance(M939A2):


Fan drivebelt and drivebelttensioner (M939A2)replacement:


Fan drivebelts (M939A1)maintenance:


Fan shroud (M939/A1),radiator, replacement:


Fan shroud (M939A2), fanand, maintenance:


Fender extension, front,replacement:


Fender, front, replacement:Installation.. ....................... 4-135b 4-698Removal.. ............................ 4-135a 4-698

Fifth wheel approach platesreplacement:


Fifth wheel deck platereplacement:

Installation.. ....................... 3-251b 3-700Removal.. ............................ 3-25 la 3-700

Fifth wheel maintenance:Assembly ............................ 4-130c 4-688Cleaning and inspection ...... 4-130b 4-686Disassembly.. ..................... 4-130a 4-682

Fifth wheel spacersreplacement:


Fifth wheel, tractor,replacement:


Filer, air dryer, replacement:Installation.. ....................... 3-465b 3-1276Removal.. ............................ 3-465a 3-1276

Index 24

Para Page

Filler cap and spout, fuel tank,replacement:


Filter, AFC fuel pump,replacement:


Filter, crane hydraulic,maintenance:


Filter, power steering pump(M939A2), maintenance:

Cleaning.. ........................... 3-237c 3-674Filter installation.. ............. 3-237e 3-674Filter removal.. ................... 3-237a 3-674Reservoir installation.. ........ 3-237d 3-674Reservoir removal ............... 3-237b 3-674

Filter, wheel valve,replacement:


Filter, winch hydraulic oilreservoir, replacement:


Fire extinguisher mountingbracket kit replacement:


First clutch maintenance:Cleaning and inspection ...... 5-53b 5-358Establishing clearance ........ 5-53d 5-360Installation.. ....................... 5-53c 5-360Removal.. ............................ 5-53a 5-358

Flasher, turn signal,replacement:


Flex hose, fuel selector valve,replacement:


Flexible converter wiringharness maintenance:


TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Flexplate and flywheel housingmaintenance:

Assembly.. .......................... 4-43d 4-294Cleaning and inspection...... 4-43c 4-293Disassembly ....................... 4-43b 4-292Installation ......................... 4-43e 4-294Removal.. ............................ 4-43a 4-292

Floodlight control switchmaintenance:Assembly.. .......................... 3-120d 3-324Disassembly.. ..................... 3-120b 3-324Inspection.. ......................... 3-120c 3-324Installation.. ....................... 3-120e 3-325Removal.. ............................ 3-120a 3-324

Floodlight maintenance:Assembly.. .......................... 3-121c 3-328Disassembly.. ..................... 3-121b 3-326Installation.. ....................... 3-121d 3-328Removal.. ............................ 3-121a 3-326

Floodlight sealed beam lampand door (M936/A1/A2)replacement:


Floor, hinged, maintenance:Assembly.. .......................... 5-72d 5-488Cleaning and inspection ...... 5-72c 5-488Disassembly.. ..................... 5-72b 5-487Installation.. ....................... 5-72e 5-488Removal .............................. 5-72a 5-486

Flow test, injector:Adjusting and measuring

fuel delivery ...................... 5-23c 5-150Setting up test stand .......... 5-23a 5-148Testing check ball seating ... 5-23b 5-148

Fluorescent light fixturesmaintenance:


Fluorescent light tubereplacement:


Flywheel housing maintenance:Cleaning and inspection ...... 4-16b 4-130Installation.. ....................... 4-16c 4-132Removal.. ............................ 4-16a 4-130

Index 25

TM 9-2320-272-24-4

INDEX

Para Page

Flywheel housing, flexplateand, maintenance:


Flywheel ring gearmaintenance:


Fording control, deepwater,replacement:


Forward clutch maintenance:Assembly ............................ 5-47d 5-328Cleaning and inspection ...... 5-47c 5-326Disassembly.. ..................... 5-47b 5-322Installation.. ....................... 5-47e 5-331Removal.. ............................ 5-47a 5-322

Forward deck platereplacement:


Forward-rear and rear-rearaxle replacement:


Forward-rear to rear-rearpropeller shaft replacement:


Fourth clutch maintenance:Assembly ............................ 5-48d 5-336Cleaning and inspection ...... 5-48c 5-334Disassembly.. ..................... 5-48b 5-332Installation.. ....................... 5-48e 5-336Removal.. ............................ 5-48a 5-332

Frame assembly, outer,windshield and, replacement:


Frame assembly, windshield,replacement:


Frame extension, winch,replacement:


Frame parts, bonnet,replacement:


Frame repair .......................... 4-129 4-681

Index 26

Para Page

(Contd)

Frame, ceiling and,maintenance:

Cleaning and inspection...... 5-76b 5-512Installation . . . . . . . . . . . . . . . . . . . . . 5-76c 5-514Removal . . . . . . . . . . . . . . . . . . . . . . . 5-76a 5-508

Frame, under-, parts,replacement:


Fresh air inlet ductingreplacement:


Fresh air vent control assemblyreplacement:


Front and rear axle breatherreplacement:


Front and rear axle carrierdifferential maintenance:

Cleaning and inspection...... 4-100b 4-564Installation....................... 4-100c 4-565Removal . . . . . . . . . . . . . . . . . . . . . . . 4-100a 4-564

Front and rear composite lightand bracket replacement:

Composite light lampinstallation . . . . . . . . . . . . . . . . . . . 3-118n 3-320

Composite light lampremoval . . . . . . . . . . . . . . . . . . . . . . 3-118m 3-320

Front composite lightinstallation . . . . . . . . . . . . . . . . . . . 3-118b 3-311

Front composite lightremoval . . . . . . . . . . . . . . . . . . . . . . . 3-118a 3-310

Installation (M923/A1/A2).. 3-118d 3-312Installation (M929/A1/A2).. 3-118h 3-314Installation (M931/A1/A2).. 3-118j 3-316Installation (M934/A1/A2).. 3-1181 3-318Installation (M936/A1/A2).. 3-118f 3-313Removal (M923/A1/A2)....... 3-118c 3-312Removal (M929/A1/A2)....... 3-118g 3-314Removal (M931/A1/A2)....... 3-118i 3-316Removal (M934/A1/A2)....... 3-118k 3-318Removal (M936/A1/A2)....... 3-118e 3-313

Front and rear field chockanchors (M936/A1)replacement:


Front and rear lifting shackleand bracket replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-24 lb 3-684Removal . . . . . . . . . . . . . . . . . . . . . . 3-24 la 3-684

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Front and rear winch controlvalve (M930/A1/A2)replacement:


Front and rear winch controlvalve replacement:


Front and rear winch levelwind maintenance:

Assembly.. .......................... 4-174d 4-839Cleaning, inspection,

and repair......................... 4-174c 4-836Disassembly.. ..................... 4-174b 4-832Installation.. ....................... 4-174e 4-841Removal.. ............................ 4-174a 4-832

Front axle drive flangemaintenance:

Inspection.. ......................... 3-156b 4-432Installation.. ....................... 3-156c 4-432Removal .............................. 3-156a 3-432

Front axle replacement:Installation.. ....................... 4-99b 4-560Removal.. ............................ 4-99a 4-558

Front axle seal replacement:Installation.. ....................... 3-160b 3-439Removal.. ............................ 3-160a 3-439

Front axle shaft and universaljoint maintenance:

Cleaning and inspection ...... 3-154b 3-426Installation.. ....................... 3-154e 3-429Removal.. ............................ 3-154a 3-426Universal joint assembly.... 3-154d 3-428Universal joint disassembly 3-154c 3-428

Front brake actuator repair:Adjustable actuator

assembly .......................... 4-112e 4-598Adjustable actuatordisassembly.. ..................... 4-112a 4-596

Cleaning and inspection ...... 4-112c 4-596Stationary actuator

assembly.. ........................ 4-112d 4-598Stationary actuator

disassembly.. .................... 4-112b 4-596Front brake spider


Front bumper and platesreplacement:


Front cab mount replacement:Installation.. ....................... 3-304b 3-800Removal.. ............................ 3-304a 3-800

Front differential oil sealreplacement:


Front exhaust pipereplacement:


Front fender extensionreplacement:


Front fender replacement:Installation.. .......................Removal ..............................

Front gearcase cover and oilseal maintenance:

Cleaning and inspection......Installation.. .......................Removal.. ............................

Front gearcase covermaintenance:


Front gearcase housing andtiming pin maintenance:

Cleaning and inspection ......Front gearcase housing

installation.. .....................Front gearcase housingremoval .............................

Timing pin installation.. .....Timing pin removal.. ...........

Front hub and drum(M939/A1) maintenance:

Cleaning and inspection......Installation.. .......................Lubrication.. .......................Removal ..............................

Front hub and drum(M939/A1) maintenance:

Cleaning and inspection ......Installation.. .......................Lubrication.. .......................Removal.. ............................

Front hubs repair:Cleaning and inspection ......Installation.. .......................Removal ..............................Repair.. ...............................

4-102b 4-5744-102a 4-574

3-50b 3-1443-50a 3-144

3-300b 3-7943-300a 3-794

4-135b 4-6984-135a 4-698

4-48b 4-3064-48c 4-3064-48a 4-306

4-18d 4-1404-18c 4-1404-18b 4-1384-18e 4-1424-18a 4-138

4-46c 4-300

4-46e 4-302

4-46a 4-3004-46d 4-3024-46b 4-300

3-223b 3-6403-223d 3-6403-223c 3-6403-223a 3-638

3-223b 3-6403-223d 3-6403-223c 3-6403-223a 3-638

3-460b 3-12533-460d 3-12563-460a 3-12523-460c 3-1254

Index 27

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Front lights cable assembly(M939/A1) replacement:


Front limiting valvereplacement:


Front relay valve replacement:Installation.. ....................... 3-187b 3-516Removal.............................. 3-187a 3-516

Front spring and main leafreplacement:

Front spring main leafinstallation ....................... 3-161c 3-443

Front spring main leafremoval ............................. 3-161b 3-443

Front spring installation ..... 3-161d 3-444Front spring removal .......... 3-161a 3-440

Front spring bumperreplacement:


Front spring bushingmaintenance:

Inspection.. ......................... 3-163a 3-448Installation.. ....................... 3-163c 3-448Removal.. ............................ 3-163b 3-448

Front spring shacklereplacement:


Front sump tube maintenance:Inspection.. ......................... 3-9b 3-36Installation.. ....................... 3-9c 3-36Removal .............................. 3-9a 3-36

Front wall registersreplacement:


Front wheel valvemaintenance:


Front winch automatic brakeadjustment:

Adjustment ......................... 3-323b 3-826Testing.. ............................. 3-323a 3-824

Front winch cable chain andhook replacement:


Front winch cable replacement:Installation.. ....................... 3-327b 3-834Removal.. ............................ 3-327a 3-834

Front winch cable tensionermaintenance:


Front winch control valve cablereplacement:


Front winch drag brakeadjustment:

Adjustment.. ....................... 3-324b 3-828Testing.. ............................. 3-324a 3-828

Front winch hydraulic hose andtube replacement:


Front winch hydraulic pumpreplacement:


Front winch motorreplacement:


Front winch repair:Assembly ofsubassemblies.. .................. 4-172d 4-819Assembly of winch.. ............ 4-172e 4-823Cleaning, inspection,

and repair.. ....................... 4-172c 4-816Disassembly into

subassemblies.. ................ 4-172a 4-810Disassembly of

subassemblies.. ................ 4-172b 4-812Front winch replacement:


Front winch roller assemblymaintenance:


and repair.. ....................... 4-175c 4-844Disassembly.. ..................... 4-175b 4-843Installation.. ....................... 4-175e 4-847Removal.. ............................ 4-175a 4-842

Front wiring harness(M939/A1) replacement:


Front wiring harness (M939A2)replacement:


Index 28

Para Page

Front, axle, seal, replacement:Installation.. ....................... 3-160b 3-439Removal.. ............................ 3-160a 3-439

Front-wheel drive lock-inswitch replacement:


Fuel can bracket replacement:Installation.. ....................... 4-187b 4-896Removal.. ............................ 4-187a 4-896

Fuel crossover connectors andcrossheads replacement:



Fuel drain and bypass tubing(M939/A1) replacement:


Fuel filter and covermaintenance:

Cleaning and inspection ...... 3-30c 3-106Installation (M939/A1)........ 3-30d 3-106Installation (M939A2). ........ 3-30e 3-107Removal (M939/A1). ............ 3-30b 3-105Removal (M939A2). ............. 3-30a 3-104

Fuel injection pumpcalibration:

Cylinder phasing (timing) .... 5-37b 5-266External stop setting.. ........ 5-37m 5-278Fuel breakaway test.. ......... 5-37j 5-277Fuel delivery test.. .............. 5-37i 5-276Full load delivery.. .............. 5-37g 5-274

High-speed fuel deliverytest.. ................................. 5-37d 5-270

Lock timing.. ....................... 5-37c 5-268Low idle fuel delivery test ... 5-371 5-278Low-speed fuel delivery

test.. ................................. 5-37e 5-270Manifold pressure

compensator test.. ............ 5-37h 5-275Prestroke and racktravel ................................ 5-37a 5-262

Rated speed test.. ............... 5-37f 5-272Starting fuel delivery test.... 5-37k 5-277

Fuel injection pumpmaintenance:


TM 9-2320-272-24-4

INDEX (Contd)

Para

Fuel injection pumpmaintenance:

Barrel and control rackremoval.. ........................... 5-36c

Camshaft installation.. ....... 5-36iCamshaft removal .............. 5-36aCleaning and inspection ...... 5-36dDelivery valve and

barrel installation.. ........... 5-36fLeakage test.. ..................... 5-36ePlunger and control rack

installation.. ..................... 5-36gTappet and plunger

removal.. ........................... 5-36bTappet and spring

installation.. ..................... 5-36hFuel injection pump pretest:

Cylinder phasing (timing) .... 5-32bFuel breakaway test.. ......... 5-32jFuel delivery test.. .............. 5-32iFull load delivery.. .............. 5-32fHigh-speed fuel delivery

test.. ................................. 5-32cLow idle fuel delivery test ... 5-321Low speed fuel delivery

test.. ................................. 5-32dManifold pressure

compensator test .............. 5-32gPrestroke and racktravel.. .............................. 5-32a

Rated speed test.. ............... 5-32eStarting cut out test.. .......... 5-32hStarting fuel delivery test.... 5-32k

Fuel injection pump, mountingto test stand:

Mounting fuel injectionpump to test stand.. ......... 5-31a

Removing fuel injectionpump from test stand.. ..... 5-31b

Fuel injector calibration:Leakage test.. ..................... 4-56bOpening pressure test.. ....... 4-56aSpray pattern test.. ............ 4-56c

Fuel injector maintenance:Assembly.. .......................... 4-55dCleaning and inspection...... 4-55cDisassembly.. ..................... 4-55bInstallation.. ....................... 4-55eRemoval.. ............................ 4-55a

Fuel injector repair:Inspection.. ......................... 5-19cNon-top stop injector

assembly .......................... 5-19d

Page

5-2465-2585-2405-248

5-2525-250

5-254

5-244

5-256

5-2165-2225-2205-220

5-2185-222

5-218

5-220

5-2145-2185-2205-222

5-210

5-212

4-3364-3364-337

4-3344-3324-3304-3344-330

5-19c

5-19d

Index 29

TM 9-2320-272-24-4

INDEX (Contd)

Para

Non-top stop injectordisassembly.. .................... 5-19a

Top stop injector assembly. 5-19eTop stop injector

disassembly.. .................... 5-19bFuel injector sleeve

maintenance:Bead cutting.. ..................... 5-6bCheck and test.. .................. 5-6eFitting and forming.. ........... 5-6dInstallation.. ....................... 5-6cRemoval.............................. 5-6a

Fuel injector tube (M939A2)maintenance:

Cleaning and inspection...... 3-19bInstallation.. ....................... 3-19cRemoval .............................. 3-19a

Fuel level sending unitreplacement:

Installation.. ....................... 3-92bRemoval.. ............................ 3-92a

Fuel pressure switch, etherstart, (M939/A1)replacement: 3-34b

Installation.. ....................... 3-34aRemoval..............................

Fuel pressure transducer(M939/A1) replacement:

Installation.. ....................... 3-96bRemoval.. ............................ 3-96a

Fuel primer pump (M939/A1)replacement:

Installation.. ....................... 3-40bRemoval .............................. 3-40a

Fuel pump filter, AFC,replacement:

Installation.. ....................... 3-3 lbRemoval.. ............................ 3-3 la

Fuel pump housingmaintenance:

Assembly ............................ 5-15cDisassembly.. ..................... 5-15aInspection.. ......................... 5-15b

Fuel pump replacement:Installation.. ....................... 4-35bOn-engine adjustments....... 4-35cRemoval.. ............................ 4-35a

Fuel pump setup andcalibration:

Checking and adjustinggovernor weight pressure.. 5-181

Checking and adjustingthrottle lever travel.. ......... 5-18h

Fuel pump run-in.. .............. 5-18c

Page Para

5-1225-132

5-126

5-285-325-305-285-26

3-643-643-62

3-2643-264

3-1133-113

3-2713-271

3-1223-122

3-1083-108

5-965-965-96

4-2624-2644-260

5-116

5-1145-108

Mounting pump totest stand . . . . . . . . . . . . . . . . . . . .

Shutdown and removalfrom test stand . . . . . . . . . . . . . . . . .

Testing and adjustingfuel pressure . . . . . . . . . . . . . . . .

Testing and adjustinggovernor fuel pressure . . . . . . .

Testing and adjustingidle speed (VS governoronly).. . . . . . . . . . . . . . . . . . . . . . . . .

Testing and adjustingidle speed . . . . . . . . . . . . . . . . . . . .

Testing and adjustingpump main pressure . . . . . . . . .

Testing and adjustingthrottle leakage . . . . . . . . . . . . .

Testing governor cutoff . . . . . . . .Testing pump seals for

leaks . . . . . . . . . . . . . . . . . . . . . . . . .Throttle shaft cover

removal. . . . . . . . . . . . . . . . . . . . . .Fuel pump shutoff valve

(M936) replacement:Installation . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . .

Fuel pump shutoff valvereplacement:

Fuel pump shutoff valveinstallation . . . . . . . . . . . . . . . . . . .

Fuel pump shutoff valveremoval... . . . . . . . . . . . . . . . . . . . .

Manual shutoff valveinstallation . . . . . . . . . . . . . . . . . . .

Manual shutoff valveremoval... . . . . . . . . . . . . . . . . . . . . .

Fuel pump with VS governorfilter replacement:


Fuel selector valve flex hosereplacement:

Installation . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . .

Fuel selector valve switchreplacement:


Fuel selector valve, mountingbracket, and indicator platemaintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . .

5-18b 5-106

5-18n 5-119

5-18j 5-116

5-18k 5-116

5-18m 5-118

5-18g 5-112

5-18i 5-114

5-18f 5-1125-18e 5-110

5-18d 5-110

5-18a 5-104

4-37b 4-2684-37a 4-268

4-36c 4-266

4-36b 4-266

4-36d 4-266

4-36a 4-266

3-32b 3-1103-32a 3-110

3-23b 3-743-23a 3-74

3-109b 3-2963-109a 3-296

3-24b 3-763-24c 3-773-24a 3-76

Page

Index 30

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Fuel system (M939A2),priming:

Priming.. ............................. 3-22 3-72Fuel tank (M936/A1/A2)

maintenance:Draining.. ........................... 3-27a 3-84Inspection.. ......................... 3-27c 3-88Installation.. ....................... 3-27d 3-88Removal.. ............................ 3-27a 3-84

Fuel tank filler cap and spoutreplacement:


Fuel tank hangers andretaining strapsmaintenance:


Fuel tank lines (M939A2)replacement:


Fuel tank maintenance:Draining.. ........................... 3-26a 3-80Inspection.. ......................... 3-26c 3-82Installation.. ....................... 3-26d 3-82Removal.. ............................ 3-26b 3-80

Fuel tank vent system kit,atmospheric, replacement:


Fuel transfer pump and supplylines (M939A2) maintenance:


G

Gauge, air, replacement:Installation . . . . . . . . . . . . . . . . 3-87b 3-252Removal . . . . . . . . . . . . . . . . . . . 3-87a 3-252

Gauges, electlricalreplacement:

Installation . . . . . . . . . . . . . . . . . 3-86b 3-250Removal . . . . . . . . . . . . . . . . . . . . 3-86a 3-250

Gear (on-vehicle), powersteering, adjustment:

Sector shaft adjustment...... 4-125a 4-668Wormshaft adjustment....... 4-125b 4-668

Gear (Ross), steering, repair:Assembly.. ..........................Cleaning, inspection

and repair.. .......................Disassembly.. .....................Final adjustment.. ..............

Gear (Sheppard), steering,repair:

Assembly.. ..........................Cleaning, inspection,


Gear unit and main shaftmaintenance:

Assembly ............................Cleaning and inspection ......Disassembly.. .....................Installation.. .......................Removal ..............................

Gear, camshaft and,maintenance:

Assembly.. ..........................Check backlash.. .................Cleaning and inspection ......Disassembly.. .....................Installation.. .......................Removal.. ............................

Gear, camshaft and,maintenance:

Assembly.. ..........................Cleaning and inspection ......Check backlash and

end play.. ..........................Disassembly.. .....................Installation.. .......................Removal ..............................

Gear, crankshaft and,maintenance:

Assembly.. ..........................Check end play ...................Cleaning and inspection......Disassembly.. .....................Installation.. .......................Removal ..............................

Gearcase cover, front,maintenance:


4-119c 4-631

4-119b 4-6304-119a 4-6244-119d 4-638

4-120c 4-648

4-120b 4-6454-120a 4-640

5-51d 5-3515-51c 5-3505-51b 5-3485-51e 5-3535-51a 5-348

5-9e 5-625-9a 5-585-9d 5-605-9c 5-605-9f 5-625-9b 5-58

5-27e 5-1805-27d 5-178

5-27a 5-1745-27c 5-1765-27f 5-1815-27b 5-176

5-29e 5-2025-29a 5-1965-29d 5-1995-29c 5-1985-29f 5-2025-29b 5-197

4-18d 4-1404-18c 4-1404-18b 4-1384-18e 4-1424-18a 4-138

Index 31

TM 9-2320-272-24-4

INDEX (Contd)

Gearcase, crane swinger,repair:

Assembly.. ..........................Cleaning, inspection,


Gearcase, crane swinger,replacement:


General ...................................General assembly.. .................General cleaning.. ...................General disassembly ..............General information ................General inspection.. ................General inspection and

servicing instructions ............General maintenance

instructions.. .........................General repair ........................General service upon receipt ...Generator, speed signal,


Glass, cab door, maintenance:Adjustment.. .......................Installation.. .......................Removal..............................

Glass, cab door, repair:Assembly.. ..........................Disassembly.. .....................

Glossary .................................Gondola replacement:


Governor piping and capacitormaintenance:

Inspection.. .........................Installation.. .......................Removal ..............................

Governor spring packmaintenance:

Inspection.. .........................Installation .........................Removal ..............................

Governor weight maintenance:Inspection.. .........................Installation.. .......................Removal ..............................

Governor, air, maintenance:Adjustment.. .......................Installation.. .......................Removal ..............................Testing ...............................

Para Page

5-107c 5-634

5-107b 5-6325-107a 5-630

4-200b 4-9364-200a 4-9364-70 4-4652-18 2-582-14 2-542-17 2-584-115 4-6052-15 2-56

2-6 2-2

5-39 5-2812-16 2-572-5 2-1

3-47 l b 3-12883-47 l a 3-1288

3-314c 3-8133-314b 3-8133-314a 3-813

4-137b 4-7064-137a 4-7061-11 1-3

4-202b 4-9444-202a 4-942

3-135b 3-3663-135c 3-3683-135a 3-364

5-14b 5-945-14c 5-955-14a 5-94

5-17b 5-1025-17c 5-1025-17a 5-102

3-207d 3-5823-207b 3-5803-207a 3-5803-207c 3-582

Para Page

Governor, air, maintenance:Adjustment . . . . . . . . . . . . . . . . . 3-207d 3-582Installation . . . . . . . .. . . . . . . . . 3-207b 3-580Removal . . . . . . . . . . . . . . . . . . . . 3-207a 3-580Testing . . . . . . . . .. . . . . . . . . . . . 3-207c 3-582

Governor, transmission,replacement:


Grab handle, cab, replacement:Installation . . . . . . . . . . . . . . . . 3-288b 3-773Removal . . . . . . . . . . . . . . . . . . . 3-288a 3-773

Grab handle, hood,replacement:

Installation . . . . . . . . . . . . . . . . . 3-271b 3-737Removal . . . . . . .. . . . . . . . . . . . . . 3-271a 3-737

Ground cable, battery,maintenance:

Connection . . . . . . . . . . . . . . . . . 3-126b 3-338Disconnection . . . . . . . . . . . . . . 3-126a 3-338

Ground strap replacement:Ground strap (M939/A1)

installation . . . . . . . . . . . .. . . . . 3-129b 3-344Ground strap (M939A2)

installation . . . . . . . . . . . . . . . . 3-129d 3-346Ground strap (M939/A1)

removal . . . . . . . . . . . . . . . . . . . 3-129a 3-344Ground strap (M939A2)

removal . . . . . . . . . . . . . . . . . . . 3-129c 3-346

H

Hand airbrake air supply valvereplacement:

Installation . . . . . . . . . . . . . . . . . 3-422b 3-1084Removal . . . . . . .. . . . . . . . . . . . . 3-422a 3-1084

Hand airbrake controller valvereplacement:

Installation . . . . . . . . . . . . . . . . . 3-423b 3-1086Removal . . . . . .. . . . . . . . . . . . . . 3-423a 3-1086

Hand airbrake doublecheckvalves replacement:

Installation (forward-rearaxle doublecheck valve)..... 3-424b 3-1088

Installation (rear-rearaxle doublecheck valve)..... 3-424d 3-1090

Removal (forward-rearaxle doublecheck valve)..... 3-424a 3-1088

Removal (rear-rear axledoublecheck valve) . . . . . . . . . . 3-424c 3-1090

Hand airbrake tractorprotection valve replacement:


Index 32

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Hand control valve(M931/A1/A2, M932/A1/A2),trailer airbrake, replacement:

Installation . . . . . . . .. . . . . . . . . . 3-210b 3-598Removal . . . . . . . . . . . . . . . . . . . 3-210a 3-598

Handle, and control rod,bonnet, replacement:

Installation . . . . . . . . . . . . . . . . 3-36 lb 3-900Removal . . . . . . . . .. . . . . . . . . . 3-36 la 3-900

Handle, and lock, door,replacement:


Handle, inside door, windowregulator and, replacement:

Installation . . . . . . . . . . . . . . . 3-308b 3-807Removal . . . . . . . . . . . . . . . . . 3-308a 3-807

Handrail modification kit,(M934/A1/A2), van,replacement:

Door check spacerinstallation . . . . . . . . . . . . .. . . 3-450h 3-1229

Door check spacerr e m o v a l . . . . . . . . . . . . . . . . 3-450g 3-1229

Ladder handrail guideinstallation . . . . . . . . . . . . . . 3-450b 3-1225

Ladder handrail guideremoval . . . . . . . . . . . . . . . . . . 3-450a 3-1225

Ladder handrail hangersinstallation . . . . . . . . . . . . . . 3-450d 3-1226

Ladder handrail hangersremoval . . . . . . . . . .. . . . . . . . . 3-450c 3-1226

Van door grab handlesinstallation . . . . . . . . . . . . . . 3-450f 3-1228

Van door grab handlesremoval . . . . . . . . . . . . . . . 3-450e 3-1228

Hangers and retaining straps,fuel tank, maintenance:

Inspection . . . . . . .. . . . . . . . . . 3-28b 3-94Installation . . . . . . . .. . . . . . . . 3-28c 3-94Removal . . . . . . . . . . . . . . . . . . 3-28a 3-92

Hard top kit replacement:Installation . . . . . . . . . . . . . . . . 3-396b 3-972Removal . . . . . . . . . . . . . . . . . . . 3-396a 3-972

Harness (M939/A1), enginecoolant heater, replacement:

Installation . . . . . . . . . .. . . . . . . 3-400b 3-980Removal . . . . . . . . . . . . . . . . . 3-400a 3-980

Harness (M939A2), enginecoolant heater, replacement:

Installation . . . . . . . . . . . . . . . 3-401b 3-982Removal . . . . . . . . . . . . . . . . . . 3-401a 3-982

Harness conduit, 400 Hzconverter, replacement:

Ins ta l la t ion . . . . . . . . . . . . . . . . 4-164b 4-794Removal . . . . . . . . . . . . . . . . . . 4-164a 4-794

Harness, 100-amp alternator,replacement:


Harness, circuit breaker and,circuit breaker maintenance:

Circuit breaker harnessinstallation.. .....................

Circuit breaker harnessremoval.. ...........................

Circuit breakerinstallation.. .....................

Circuit breaker removal.. ....Repair.................................

Harness, convoy warning light(M929/A1/A2, M930/A1/A2),replacement:


Harness, convoy warning light,replacement:


Harness, instrument cluster,replacement:


Harness, right and left sideblackout, maintenance:

Installation.. .......................Removal.. ............................Repair.................................

Harness, right and left sideblackout, maintenance:

Installation.. .......................Removal ..............................Repair .................................

Harness, swingfire heater,replacement:


Harness, wiring, repair:Female cable connector

(with sleeve). .....................Male cable connector.. .........Plug assembly ....................Receptacle assembly.. .........Terminal-type cable

connector.. .........................Head, cylinder, replacement:


3-427b 3-10983-427a 3-1096

4-158e 4-770

4-158a 4-770

4-158d 4-7704-158b 4-7704-158c 4-770

3-434b 3-11183-434a 3-1116

3-433b 3-11143-433a 3-1114

3-130b 3-3483-130a 3-348

4-157c 4-7684-157a 4-7684-157b 4-768

5-98c 5-6005-98a 5-5985-98b 5-600

3-408b 3-10123-408a 3-1010

3-131c 3-3503-131b 3-3503-131d 3-3503-131e 3-350

3-131a 3-349

4-12b 4-1224-12a 4-120

Index 33

TM 9-2320-272-24-4

INDEX

Para Page

Head, oil cooler filter,transmission, replacement:

Oil cooler filterinstallation . . . . . . . . . . . . . . 3-139d 3-377

Oil cooler filter headinstallation . . . . . . . . . . . . . . 3-139c 3-377

Oil cooler filter headremoval . . . . . . . . . . . . . . . . . 3-139b 3-376

Oil cooler filter removal....... 3-139a 3-376Header plates, water,

replacement:Installation . . . . . . . . . . . . . . . . 4-28b 4-198Removal . . . . . . . . . . . . . . . . . 4-28a 4-198

Headlight maintenance:Alignment . . . . . . . . . . . . . . 3-116c 3-306Installation . . . . . .. . . . . . . 3-116b 3-306Removal . . . . . . . . .. . . . . . . . 3-116a 3-306

Heat shield accessroy, exhaust,replacement:

I n s t a l l a t i o n . . . . . . . . . . . . . . . 3-449b 3-1224Removal . . . . . . . . . . . . . . . .. . . . 3-449a 3-1224

Heater (M933/A1), personnelfuel burning, replacement:

Installation . . . . . . . . . . . . . . . 4-215b 4-1004Removal . . . . . . . . . . . . . . . 4-215a 4-1004

Heater and exhaust, van,replacement:

I n s t a l l a t i o n . . . . . . . . . . . . . . . 3-379b 3-930Removal . . . . . . . . . . . . . . . 3-379a 3-928

Heater control box, enginecoolant, replacement:

Installation . . . . . . . . . . . . . . . . 3-399b 3-978Removal . . . . . . . . . . . . . . . . . 3-399a 3-978

Heater exhaust tube(M939/A1), personnel fuelburning, replacement:

Installation . . . . .. . . . . . . . . . 4-222b 4-1020Removal . . . . . . . . . . . . . . . . . 4-222a 4-1020

Heater exhaust tube (M939A21,personnel fuel burning,replacement:

Installation . . . . . . . . . . 4-223b 4-1022Removal . . . . . . . . . . . . . . . . . . 4-223a 4-1022

Heater fuel pump(M934A1/A2), van,replacement:

Installation (M934) . . . . . . . . 3-381d 3-936Installation (M934A1/A2)... 3-381b 3-934Removal (M934). . . . . . . . . .. . 3-381c 3-936Removal (M934A1/A2)...... 3-381a 3-934

Heater fuel pump wiringharness maintenance:

Installation . . . . . . . . . . .. . . . . 4-156c 4-766Removal . . . . . . . . . . . . . . . . 4-156a 4-766Repair . . . . . . . . . . . . . . . . . . . . . 4-156b 4-766

Index 34

(Contd)

Para Page

Heater pad, swingfire heaterbattery box, replacement:

Installation . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . .

Heater pump, engine coolant,replacement:

I n s t a l l a t i o n . . . . . . . . . . . . .Removal.. . . . . . .. . . . . . . . .

Heater thermostat and 10 kWheater thermostatreplacement:

10 kW heater thermostatinstallation . . . . . . . . . . . . .

10 kW heater thermostatremoval . . . . . . . . . . . . . . . . .

Heater thermostatinstallation . . . . . . . . . . . . . . .

Heater thermostatremoval. . . . . . . . . . .

Heater, circuit breaker,personnel fuel burning,replacement:

3-410b 3-10183-410a 3-1018

3-398b 3-9763-398a 3-976

4-165d 4-796

4-165b 4-796

4-165c 4-796

4-165a 4-796

Installation . . . . . . . . .. .Removal . . . . . . . . . . . . . . . .

Heater, electric fuel pump(M939A1), personnel fuelburning, replacement:

Installation . . . . . . . . . . . . .. . .Removal.. . . . . . . . . . . . . . . . .

Heater, electric fuel pump(M939A2), personnel fuelburning, replacement:

I n s t a l l a t i o n . . . . . . . . . . . . .Removal. . . . . . . . . . . . . . . . .

Heater, electrical components,swingtire, replacement:

Circuit breakerinstallation . . . . . . . . . . . . . .

Circuit breaker removal . . . .Electrical connecter

installation . . . . . . . . . . . . .Electrical connector

removal . . . . . . . . . . . . . . . . .Relay installation . . . . . .. . .Relay removal . . . . . . . . . . . .Thermal switch

installation . . . . . . . . . . . . .. .Thermal switch removal . . . .

Heater, fuel shutoff valve,personnel fuel burning,replacement:

4-224b 4-10244-224a 4-1024

4-218b 4-10104-218a 4-1010

4-219b 4-10124-219a 4-1012

3-407f 3-10063-407c 3-1006

3-407h 3-1008

3-407a 3-10043-407g 3-10083-407b 3-1004

3-407e 3-10063-407d 3-1006

Installation . . . . . . . . . . . . . . 4-220b 4-1014Removal.. . . . . . . . . . . . . . . . . . 4-220a 4-1014

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Heater, mounting bracket andswingtire, replacement:


Heater, personnel, hot water,replacement:


Heater, wiring harness,personnel fuel burning,replacement:


High-beam selector switchreplacement:


Hinge, and seal, door,replacement:


Hinge, hood, replacement:Installation.. ....................... 4-133b 4-694Removal.. ............................ 4-133a 4-694

Hinged end panel maintenance:Assembly.. .......................... 4-155d 4-764Cleaning and inspection ...... 4-155c 4-763Disassembly.. ..................... 4-155b 4-762Installation.. ....................... 4-155e 4-764Removal.. ............................ 4-155a 4-762

Hinged floor maintenance:Assembly.. .......................... 5-72d 5-488Cleaning and inspection ...... 5-72c 5-488Disassembly.. ..................... 5-72b 5-487Installation.. ....................... 5-72e 5-488Removal.. ............................ 5-72a 5-486

Hinged roof and floorcounterbalance cablemaintenance:

Cable adjustment.. ............. 3-356c 3-895Installation.. ....................... 3-356b 3-894Removal.. ............................ 3-356a 3-894

Hinged roof maintenance:Assembly.. .......................... 5-77d 5-526Cleaning and inspection ...... 5-77c 5-524Disassembly.. ..................... 5-77b 5-520Installation.. ....................... 5-77e 5-530Removal.. ............................ 5-77a 5-518

Hinged roof-operated blackoutcircuit plungers replacement:


Para Page

Hoist level wind maintenance:Assembly.. .......................... 4-191c 4-906Disassembly.. ..................... 4-191b 4-906Installation.. ....................... 4-191d 4-906Removal.. ............................ 4-191a 4-906

Hoist winch cable replacement:Installation.. ....................... 3-384b 3-944Removal.. ............................ 3-384a 3-942

Hoist winch replacement:Installation.. ....................... 4-192b 4-908Removal.. ............................ 4-192a 4-908

Holding future, mounting fuelpump to:


Holding fixture, transmissionmounting to:

Installation.. ....................... 5-40a 5-284Removal.. ............................ 5-40b 5-282

Hood bumper replacement:Installation.. ....................... 3-274b 3-741Removal .............................. 3-274a 3-741

Hood crossmember bracketmaintenance:


Hood grab handle replacement:Installation.. ....................... 3-27 lb 3-737Removal.. ............................ 3-271a 3-737

Hood hinge replacement:Installation.. ....................... 4-133b 4-694Removal.. ............................ 4-133a 4-694

Hood latch and bracketreplacement:


Hood retaining bracketreplacement:


Hood stop bracket, cab,replacement:


Hood stop cables replacement:Installation.. ....................... 3-270b 3-736Removal.. ............................ 3-270a 3-736

Hood support bar and bracketreplacement:


Hood, engine, maintenance:Adjustment.. ....................... 3-275c 3-746Installation.. ....................... 3-275b 3-744Removal .............................. 3-275a 3-742

Index 35

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Hook, pintle, maintenance:Assembly.. .......................... 3-242d 3-687Cleaning and inspection ...... 3-242c 3-686Disassembly.. ..................... 3-242b 3-686Installation.. ....................... 3-242e 3-687Removal.. ............................ 3-242a 3-686

Hook, side panel roof swivel,replacement:


Horn contact brushreplacement:


Horn switch replacement:Installation.. ....................... 3-104b 3-286Removal.. ............................ 3-104a 3-286

Horn, solenoid, and bracketreplacement:


Hose (M939A2), air cleaner,maintenance:


Hose chafe guard kit, hydraulic,replacement:


Hose, deepwater fording airpressure, replacement:

Installation (M939/A1)....... 4-227d 4-1038Installation (M939A2). ....... 4-227c 4-1034Removal (M9391A1). ........... 4-227a 4-1034Removal (M939A2). ............ 4-227b 4-1036

Hose, heater inlet and outlet,personnel, replacement:


Hose, heater, engine coolant,replacement:


Hoses and brackets (M939A2),upper radiator, replacement:


Hoses and lines (M939A2),coolant, replacement:


Para Page

Hoses and tubes (M939/A1),coolant, replacement:

Radiator inlet hoses andtube installation . . . . . . . . . . . 3-54j 3-158

Radiator inlet hoses andtube removal . . . . . . . . . . . . . . 3-54a 3-154

Radiator outlet hoses andtee installation . .. . . . . . . . . 3-54g 3-156

Radiator outlet hoses andtee removal . . . . . . . . . . . . . . . 3-54d 3-156


radiator bypass tube, andhose installation . . . . . . . . . . 3-54i 3-158

Thermostat housing hose,radiator bypass tube, andhose removal . . . . . . . . . . . . . 3-54b 3-154


Transmission oil coolerhoses and tube removal.... 3-54e 3-156

Hoses, oil cooler, transmission,replacement:

Installation . . . . . . . . . . . . . . . . 3-142b 3-388Removal . . . . . . . . . . . . . . . . . . . 3-142a 3-384

Hoses, power steering pumppressure and return,replacement (Ross):


Hoses, power steering pumppressure and return,replacement (Sheppard):

Installation . . . . . . . . . . . . . . . . . . 3-235b 3-670Removal . . . . . . . . . . . . . . . . . . 3-235a 3-670

Hoses, steering assist cylinder,replacement:


Housing (M939A2),thermostats and,maintenance:

Cleaning and inspection...... 3-66b 3-193Installation (external

bypass) . . . . . . . . . . . . . . . . . . . 3-66e 3-194Installation (internal

bypass) . . . . . . . . . . . . . . . . . . . . . . . 3-66c 3-193Removal (external bypass).. 3-66d 3-194Removal (internal bypass).. 3-66a 3-192

Housing assembly coverreplacement:


Index 36

INDEX

Para Page

Housing, adapter and firstcluth piston, maintenance:

Assembly ............................ 5-57d 5-380Cleaning and inspection ...... 5-57c 5-380Disassembly.. ..................... 5-57b 5-378Removal.. ............................ 5-57a 5-378

Housing, cam follower,maintenance:


Housing, flywheel,maintenance:


Housing, fuel pump,maintenance:

Assembly.. .......................... 5-15c 5-96Disassembly.. ..................... 5-15a 5-96Inspection.. ......................... 5-15b 5-96

Housing, hydraulicoil filter,replacement:


Housing, transmission,maintenance:


Hub air seal leak test:Front hub leak test.. ........... 3-462a 3-1264Rear hub leak test.. ............ 3-462b 3-1266

Hub and drum (M939/A1),front, maintenance:

Cleaning and inspection...... 3-223b 3-640Installation.. ....................... 3-223d 3-640Lubrication.. ....................... 3-223c 3-640Removal.. ............................ 3-223a 3-638

Hub and drum (M939/A1),rear, maintenance:

Cleaning and inspection...... 3-224b 3-644Installation.. ....................... 3-224d 3-646Lubrication ......................... 3-224c 3-644Removal.. ............................ 3-224a 3-642

Hubs, front, repair:Cleaning and inspection ...... 3-460b 3-1253Installation.. ....................... 3-460d 3-1256Removal .............................. 3-460a 3-1252Repair.. ............................... 3-460c 3-1254

TM 9-2320-272-24-4

(Contd)

Hubs, rear, repair:

Para Page

Cleaning and inspection. . . . . . 3-461b 3-1260Installation . . . . . . . . . . . . . . . . 3-461d 3-1262Removal . . . . . . . . . . . . . . . . . . . 3-461a 3-1258Repair. . . . . . . . . . . . . . . . . . . 3-461c 3-1260

Hydraulic hoist winch motorand lines replacement:


Hydraulic hose chafe guard kitreplacement:

Installation . . . . . . . . . . . . . . . . . 3-443b 3-1150Removal . . . . . . . . . . . . . . . . . . . . . 3-443a 3-1148

Hydraulic oil filter housingreplacement:

Installation . . . . . . . . . . . . . . . . 4-186b 4-894Removal . . . . . . . . . .. . . . . . . . . . 4-186a 4-894

Hydraulic oil reservoir bracketsand straps replacement:

Installation . . . . . . . . . . . . . . . . . . 4-189b 4-902Removal . . . . . . . . . . . . .. . . . . . . 4-189a 4-902

Hydraulic oil reservoirmaintenance:

Assembly . . . . . . . . . . . . . . . . . . . 4-188d 4-900Cleaning, inspection,

and repair . . . . . .. . . . . . . . . . . . 4-188c 4-900Disassembly . . . . . . . . . . . . . . . . 4-188b 4-898Installation . . . . . . . . . . . . . . . . . . 4-188e 4-900Removal . . . . . . . . . . . . . . . . . . . . 4-188a 4-898

Hydraulic reservoir drain kitreplacement:


Hydraulic reservoir shutoffmodification kit replacement:

Installation . . . . . . . . . . . . . . . 3-445b 3-1156Removal . . . . . . . . . . . . . . . . . . . 3-445a 3-1154

Hydraulic system operation..... 1-24 1-71

I

Idle speed, engine run-in testand, adjustment:

Engine run-in test . . . . . . . . . . . 4-54a 4-328Idle speed adjustment . .. . . . . 4-54b 4-328

Indicator lamp, turn signalcontrol and, replacement:


Indicator panel light and lampreplacement:

Lamp installation . . . . . . . . . . . . 3-84d 3-246Lamp removal . . . . . . . . . . . . . . 3-84c 3-246Light assembly installation. 3-84b 3-246Light assembly removal...... 3-84a 3-246

Index 37

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Indicator plate, fuel selectorvalve, mounting bracket, and,maintenance:

Inspection.. ......................... 3-24bInstallation.. ....................... 3-24cRemoval.. ............................ 3-24a

Information, general ............... 4-115Injection pump, fuel,

maintenance:Adjustment.. ....................... 4-57cInstallation.. ....................... 4-57bRemoval.. ............................ 4-57a

Injector (dial indicator method),valve and, adjustment:

Checking plunger freetravel.. .............................. 4-33a

Injector and valveadjustments.. ................... 4-33b

Injector flow test:Adjusting and measuringfuel delivery ...................... 5-23c

Setting up test stand.. ........ 5-23aTesting check ball seating... 5-23b

Injector leak test:Setting up injector leakage

detector.. ........................... 5-20aTesting injector plunger

and seat.. ......................... 5-20bInjector plunger and valve

adjustments (torque method):Injector and valve

adjustment.. ..................... 4-34bPre-adjustment setup ......... 4-34a

Injector spray pattern test:Setting up spray

pattern tester.. ................. 5-21aTesting spray pattern ......... 5-21b

Injector test stand calibration:Setting up injector tester..... 5-22aTest stand calibration ........ 5-22b

Injector, fuel, calibration:Leakage test.. ..................... 4-56bOpening pressure test.. ....... 4-56aSpray pattern test.. ............ 4-56c

Injector, fuel, maintenance:Assembly.. .......................... 4-55dCleaning and inspection ...... 4-55cDisassembly.. ..................... 4-55bInstallation.. ....................... 4-55eRemoval.. ............................ 4-55a

Injector, fuel, repair:Inspection.. ......................... 5-19cNon-top stop injector

assembly .......................... 5-19d

3-763-773-764-605

4-3454-3424-338

4-248

4-248

5-1505-1485-148

5-136

5-138

4-2564-254

5-1405-140

5-1425-146

4-3364-3364-337

4-3344-3324-3304-3344-330

5-128

5-129

Non-top stop injectordisassembly.. .................... 5-19a 5-122

Top stop injector assembly. 5-19e 5-132Top stop injector

disassembly.. .................... 5-19b 5-126Inner boom replacement:


Inserts, valve seat,maintenance:

Cleaning ............................. 5-5d 5-24Counterboring.. ................... 5-5c 5-24Gauging.. ............................ 5-5b 5-22Installation.. ....................... 5-5e 5-24Removal.. ............................ 5-5a 5-22

Inside telephone jack postreplacement:


Inspection and servicinginstructions, general ............. 2-6 2-2

Inspection and servicinginstructions, specific.............. 2-7 2-2

Inspection in limited storage... 6-11 6-3Inspection, general .................. 2-15 2-56Instrument cluster harness


Instrument clustermaintenance:


Instrument panel replacement:Installation.. ....................... 3-85b 3-248Removal.. ............................ 3-85a 3-248

Insulation, cab, replacement:Installation.. ....................... 3-306b 3-804Removal.. ............................ 3-306a 3-804

Intake and exhaust valvesrefacing:

Cleaning after refacing.. ...... 5-4c 5-20Grinding or refacing

valves ............................... 5-4b 5-20Valve specifications.. ........... 5-4a 5-18

Intake pipe (M939/A1), aircleaner, maintenance:


Interior side panels andlatches replacement:


Index 38

TM 9-2320-272-24-4

INDEX (Contd)

Isolator (M939A2),transmission mountingbracket replacement:


K

Kit, A-frame, maintenance:Inspection.. .........................Installation.. .......................Removal ..............................

Kit, air dryer (M923/A1/A2,M925/A1/A2, M927/A1/A2,M928/A1/A2, M934/A1/A2)replacement:


Kit, air dryer (M929/A1/A2,M930/A1/A2, M931/A1/A2,M932/A1/A2, M936/A1/A2)replacement:


Kit, hardtop, replacement:Installation.. .......................Removal ..............................

Kit, mud guard (M931/A1/A2,M932/A1/A2), replacement:


Kit, troop seat and siderack(M929/A1/A2, M930/A1/A2)maintenance:

Siderack assembly.. ............Siderack disassembly.. .......Troop seat assembly.. .........Troop seat disassembly ......

Knuckle, steering,maintenance:

Cleaning and inspection......End play test.. ....................Installation.. .......................Removal ..............................

L

Ladder locking clampreplacement:


Ladder rack bumpersreplacement:

Installation . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . .

Para Page

3-137b 3-3733-137a 3-373

3-414b 3-10483-414c 3-10483-414a 3-1046

3-412b 3-10263-412a 3-1022

3-413b 3-10393-413a 3-1032

3-396b 3-9723-396a 3-972

3-420b 3-10783-420a 3-1078

3-429c 3-11023-429b 3-11023-429d 3-11023-429a 3-1102

4-98b 4-5524-98d 4-5564-98c 4-5544-98a 4-550

3-360b 3-8993-360a 3-899

3-366b 3-9073-366a 3-907

Para Page

Lamp and door (M936/A1/A2),floodlight, sealed beam,replacement:


Lamp and lens, emergency/blackout light, replacement:


Latch and bracket, hood,replacement:


Leak test, injector:Setting up injector leakagedetector.. ........................... 5-20a 5-136

Testing injector plungerand seat.. ......................... 5-20b 5-138

Leakage, axle, test:Corrective action ................. 4-106b 4-582Test.. .................................. 4-106a 4-582

Level wind, hoist,maintenance:


Lift eyes, engine, replacement:Installation.. ....................... 4-11b 4-118Removal.. ............................ 4-11a 4-118

Lifting shackle and bracket,front and rear, replacement:

Installation ......................... 3-24 lb 3-684Removal.. ............................ 3-24 la 3-684

Light fixtures, blackout andemergency, replacement:


Light fixtures, flourescent,maintenance:


Light switch, main,replacement:


Light tube, fluorescent,replacement:


Index 39

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Light, blackout, maintenance:Assembly.. .......................... 3-117c 3-308Disassembly.. ..................... 3-117b 3-308Installation.. ....................... 3-117d 3-308Removal.. ............................ 3-117a 3-308

Light, head-, maintenance:Alignment.. ......................... 3-116c 3-306Installation.. ....................... 3-116b 3-306Removal.. ............................ 3-116a 3-306

Lights, bracket and sidemarker, replacement:

Lamp installation.. ............. 3-122d 3-330Lamp removal.. .................. 3-122a 3-330Light installation.. .............. 3-122c 3-330Light removal.. ................... 3-122b 3-330

Lightweight weapon stationmodification kit maintenance:

Assembly.. .......................... 3-446c 3-1170Disassembly.. ..................... 3-446b 3-1168Installation.. ....................... 3-446d 3-1174Removal.............................. 3-446a 3-1160

Limited storage instructions ... 6-10 6-2Limited storage, inspection in. 6-11 6-3Limited storage, removal from 6-12 6-3Limiting valve, front,

replacement:Installation ......................... 3-190b 3-522Removal.. ............................ 3-190a 3-522

Lines (M939A2), aircompressor and, replacement:


Lines (M939A2), fuel tank,replacement:


Link, drag, replacement:Installation.. ....................... 3-229b 3-655Removal.. ............................ 3-229a 3-655

Linkage (M939/A1),accelerator, maintenance:Adjustment.. ....................... 3-42c 3-124Installation.. ....................... 3-42b 3-124Removal.. ............................ 3-42a 3-124

Linkage (M939A2), accelerator,maintenance:

Adjustment.. ....................... 3-43f 3-128Assembly.. .......................... 3-43d 3-128Cleaning and inspection ...... 3-43c 3-128Disassembly.. ..................... 3-43b 3-126Installation ......................... 3-43e 3-128Removal.. ............................ 3-43a 3-126

List of abbreviations.. ............. l-10 1-3Loading and movement .......... 6-8 6-2Location and description of

major components.. ............... 1-14 1-16

Index 40

Para Page

Lock, cab door, replacement:Installation . . . . .. . . . . . . . . . . . . 3-313b 3-812Removal . . . . . . . . . .. . . . . . . . . . 3-313a 3-812

Lock, rear, side panel,replacement:

Installation . . . . . . . . .. . . . . . . . . 3-368b 3-910Removal . . . . . . . .. . . . . . . . . . . 3-368a 3-909

Lock, side panel exterior,replacement:

Installation . . . . . .. . . . . . . . . . . 3-370b 3-912Removal . . . . . . . . . . . . . . . . . . . 3-370a 3-912

Lock, side panel front andhinged-type roof, replacement:

Installation . . . . . . . . . . . . . . . . . . 3-369b 3-911Removal . . . . . . . . . . . . . . . . . . . . . 3-369a 3-911

Lock-in control valve, transfercase front axle, replacement:


Lock-in switch, front wheel,replacement:

Installation . . . . . . . . . . . . . . . . 3-101b 3-280Removal . . . . . . . . . . .. . . . . . . . 3-101a 3-280

Locks, expanding andretracting mechanism,replacement:

Installation . . . . . . . . . . . . . . 3-378b 3-926Removal . . . . . . . . . . . . . . . . . . 3-378a 3-926

Low clutch removal andclearance:

Cleaning and inspection...... 5-56b 5-374Establishing clearance........ 5-56c 5-376Removal . . . . . . . . . . . . . . .. . . . . . 5-56a 5-374

Lower torque rod, upper and,maintenance:

Assembly . . . . . . . . . . . . . . . . . . 3-170e 3-472Cleaning and inspection...... 3-170c 3-470Diassembly. . . . . . . . . . . . . .. . . . . 3-170d 3-470Lower torque rod

installation. . . . . . . . . . . . . . . . 3-170h 3-474Lower torque rod removal... 3-170b 3-470Setting preload for upper

torque rod . . . . . . . . . . . . . . . . . 3-170f 3-472Upper torque rod

installation . . . . .. . . . . . . . . . . 3-170g 3-474Upper torque rod removal... 3-170a 3-468

Lubrication, generalpreparation of vehicle forshipment . . . . . . . . . . . . . . . . . . . 6-3 6-1

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

M

Machine gun mounting kitmaintenance:

Assembly ............................Disassembly.. .....................Installation.. .......................Removal ..............................

Main leaf, front spring and,replacement:

Front spring main leafinstallation.. .....................

Front spring main leafremoval.. ...........................

Front spring installation .....Front spring removal ..........

Main light switch replacement:Installation.. .......................Removal ..............................

Main shaft, gear unit and,maintenance:

Assembly.. ..........................Cleaning and inspection ......Disassembly.. .....................Installation.. .......................Removal ..............................

Main wiring harnessreplacement:


Maintenance forms, records,and reports.. .........................

Maintenance instructions,general ..................................

Manifold pressure compensatormaintenance:

Assembly.. ..........................Cleaning and inspection ......Installation. ........................Disassembly .......................Removal ..............................

Manifold return hose(M939/A1), surge tank,radiator vent hose and,replacement:

Radiator vent and manifoldreturn hoses installation ...

Radiator vent and manifoldreturn hoses removal ........

Surge tank installation.. .....Surge tank removal .............

3-418c 3-10703-418b 3-10683-418d 3-10723-418a 3-1066

3-161c 3-443

3-161b 3-4433-161d 3-4443-161a 3-440

3-108b 3-2943-108a 3-294

5-51d 5-3515-51c 5-3505-51b 5-3485-51e 5-3535-51a 5-348

5-89b 5-5685-89a 5-568

1-2 1-1

5-39 5-281

5-33d 5-2265-33c 5-2265-33e 5-2265-33b 5-2245-33a 5-224

3-61d 3-182

3-61a 3-1803-61c 3-1823-61b 3-180

Manifold, engine air intake,maintenance:

Assembly.. .......................... 4-24d 4-180Cleaning and inspection ...... 4-24c 4-180Disassembly.. ..................... 4-24b 4-180Installation.. ....................... 4-24e 4-182Removal .............................. 4-24a 4-178

Manifold, engine water,maintenance:


Manifold, exhaust,replacement:


Manual selector shaft,transmission, replacement:


Map compartmentreplacement:


Mechanical troubleshooting,direct and general support

symptom index ................... 4-2 4-2Mechanical troubleshooting,

unit level.. ............................. 2-21 2-61Mini-lighting kit, European,


Mirror, brace and, rearview,replacement:


Models, differences between .... 1-15 1-20Modulate lockup valve, low

trimmer valve, and low shiftvalve replacement:


Modulator, transmission,maintenance:


Motor, crane hydraulic swinger,replacement:


Index 41

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Mount (M939/A1), oil cooler,transmission, replacement:

Oil cooler installation . . . . . . . . . . 3-140d 3-379Oil cooler mount

installation . . . . . . . . . . . . . . . . . 3-140c 3-378Oil cooler mount removal . . . . 3-140b 3-378Oil cooler removal . . . . . . . . . . . . . 3-140a 3-378

Mount (M939A2), oil cooler,transmission, replacement:

Installation . . . . . .. . . . . . . . . . . 3-14 lb 3-382Removal . . . . . . . . . . . . . . . . . . . 3-14 la 3-380

Mount, convoy warning light(M929/A1/A2, M930/A1/A2),replacement:


Mount, convoy warning light(M934/A1/A2), replacement:

Installation . . . . . . . . . . . . . . . . 3-431b 3-1110Removal . . . . . .. . . . . . . . . . . . . . 3-431a 3-1108

Mount, convoy warning light,replacement:

Installation . . . . . . . . . . . . . . . . 3-430b 3-1106Removal . . . . . . . . . . . . . . . . . . . 3-430a 3-1104

Mounting bracket kit, chemicalagent alarm, replacement:

Chemical alarm wiringharness installation . . . . . . . . 3-417d 3-1064

Chemical alarm wiringharness removal . . . . . . . . . . . 3-417a 3-1058

Detector and alarm bracketinstallation . . . . . . . . . . . . . . . . 3-417c 3-1062

Detector and alarm bracketremoval . . . . . . . . . . . . . . . . . . . 3-417b 3-1060

Mounting bracket kit,decontamination (M13)apparatus, replacement:

Installation (M923/A1/A2,M925/A1/A2, M9271A1/A2,M928/A1/A2) . . . . . . . . . . . . 3-419h 3-1076

Installation (M929/A1/A2,M930/A1/A2, M931/A1/A2,M932/A1/A2) . . . . . . . . . . . . 3-419b 3-1074

Installation (M934/A1/A2).. 3-419d 3-1074Installation (M936/A1/A2).. 3-419f 3-1076Removal (M923/A1/A2,

M925/A1/A2, M927/A1/A2,M928/A1/A2).. . . . . . . . . . . . . 3-419g 3-1076

Removal (M929/A1/A2,M930/A1/A2, M931/A1/A2,M932/A1/A2) . . . . . . . . . . . . 3-419a 3-1074

Removal (M934/A1/A2)....... 3-419c 3-1074Removal (M936/A1/A2)....... 3-419e 3-1076

Mounting bracket kit, fireextinguisher, replacement:

Installation . . . . . . . . . . . . . . . . . . 3-416b 3-1056Removal . . . . . . . . . . . . . . . . . . . . . 3-416a 3-1056

Mounting bracket, air cleanerassembly and, maintenance:

Inspection . . . . . . . . . . . . . . . . . . . 3-15b 3-52Installation . . . . . . . . . . . . . . . . . 3-15c 3-54Removal . . . . . . . . . . . . . . . . . . . . . .3-15a 3-52

Mounting bracket, alernator,pulley (M939A2)maintenance:

Adjustment . . . . . . . . . . . . . . . . . . 3-80e 3-230Alternator and mounting

bracket installation . . . . . . . . . . 3-80d 3-230Alternator and mounting

bracket removal . . . . . . . . . . . . . . 3-80a 3-228Pulley installation . . . . . . . . . . . . . . 3-80c 3-230Pulley removal . . . . . . . . . . . . . . . . . 3-80b 3-229

Mounting bracket, alternator(M939/A1) and, replacement:


Mounting bracket, fuel selectorvalve, and indicator platemaintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-24b 3-76Installation . . . . . . . . . . . . . . . . . . . . . 3-24e 3-77Removal . . . . . . . . . . . . . . . . . . . . . . . 3-24a 3-76

Mounting bracket, pioneer toolkit, replacement:

Bracket installation (M923,M925, M927, M928) . . . . . . . . . 3-415b 3-1052

Bracket installation (M929,M930)........................... 3-415f 3-1054

Bracket installation(M929A1, M930A1) . . . . . . . . . 3-415h 3-1054

Bracket installation (M931,M932) . . . . . . . . . . . . . . . . . 3-415d 3-1052

Bracket removal (M923,M925, M927, M928) . . . . . . . . 3-415a 3-1052

Bracket removal (M929,M930). . . . . . . . . . . . . . . . . . . . 3-415e 3-1054

Bracket removal (M929A1,M930A1). . . . . . . . .. . . . . . . . . 3-415g 3-1054

Bracket removal (M931,M932) . . . . . . . . . . . .. . . . . . . . . 3-415c 3-1052

Mounting brackets andisolators, engine,replacement:

Installation . . . . . . .. . . . . . . . . . . 4-39b 4-274Removal . . . . . . . . . . . . . . . . . . . 4-39a 4-272

Index 42

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Mounting fuel injection pumpto test stand:

Mounting fuel injectionpump to test stand.. ......... 5-31a 5-210

Removing fuel injectionpump from test stand.. ..... 5-31b 5-212

Mounting fuel pump to holdingfixture:


Mounting kit, machine gun,maintenance:

Assembly.. .......................... 3-418c 3-1070Disassembly.. ..................... 3-418b 3-1068Installation.. ....................... 3-418d 3-1072Removal .............................. 3-418a 3-1066

Mounting kit, rifle,replacement:

Installation on left door.. .... 3-421c 3-1082Installation on dash

and floor.. ......................... 3-42ld 3-1083Removal from dash

and floor ........................... 3-421b 3-1081Removal from left door ........ 3-421a 3-1080

Mounting pins, shock absorberand, replacement:


Mounting plate (M936/Al/A2),wet air reservoir (supplytank) and, replacement:


Movement, loading and........... 6-8 6-2Mud guard kit (M931/A1/A2,

M932/A1/A2) replacement:Installation.. ....................... 3-420b 3-1078Removal.. ............................ 3-420a 3-1078

Muffler and shieldmaintenance:

Inspection ........................... 3-51b 3-146Installation.. ....................... 3-51c 3-146

. Removal.. ............................ 3-51a 3-146

N

Neutral start switch,transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-98b 3-273Removal. . . . . . . . . . . . . . . . . . . . . . . . 3-98a 3-273

O

Official nomenclature.. ............ 1-5 1-2Oil cooler, engine,

maintenance:Assembly.. .......................... 4-23d 4-176Cleaning and inspection...... 4-23c 4-176Disassembly.. ..................... 4-23b 4-174Installation.. ....................... 4-23e 4-176Removal.. ............................ 4-23a 4-174

Oil dipstick tube maintenance:Inspection ........................... 3-3c 3-8Installation (M939/A1). ...... 3-3d 3-10Installation (M939A2). ....... 3-3e 3-10Removal (M939/A1).. .......... 3-3a 3-8Removal (M939A2). ............ 3-3b 3-8

Oil pan and filter,transmission, maintenance:


Oil pan and oil suction tubemaintenance:

Cleaning and inspection ...... 4-47c 4-304Oil pan installation ............ 4-47e 4-305Oil pan removal.. ................ 4-47a 4-304Oil suction tube 4-47d 4-304

installation.. .....................Oil suction tube removal ..... 4-47b 4-304

Oil pan shroud and exhausttube, engine coolantreplacement:


Oil pan shroud and exhausttube, swingfire heater,replacement:


Oil pan, engine, maintenance:Assembly ............................ 4-22d 4-170Cleaning and inspection...... 4-22c 4-170Disassembly.. ..................... 4-22b 4-170Installation.. ....................... 4-22e 4-172Removal.. ............................ 4-22a 4-168

Oil pressure sending unitreplacement:


Oil pressure, transmission,testing:

Automatic shift speed test.. 5-60c 5-392Main pressure and

governor pressure test....... 5-60b 5-390Oil cooler pressure test.. ..... 5-60a 5-386

Index 43

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Oil pump and front support,transmission, maintenance:


Oil pump maintenance:Cleaning and inspection...... 4-49c 4-310Gear backlash test.. ........... 4-49a 4-308Installation.. ....................... 4-49d 4-310Removal.. ............................ 4-49b 4-308

Oil pump pickup hosemaintenance:


Oil pump return hosemaintenance:

Inspection.. ......................... 3-8b 3-34Installation.. ....................... 3-8c 3-34Removal ................................ 3-8a 3-34

Oil pump, engine, replacement:Gear backlash test.. ........... 4-21a 4-164Installation.. ....................... 4-21c 4-166Removal.. ............................ 4-21b 4-164

Oil reservoir (M932/A1/A2),tractor winch hydraulic,replacement:


Oil reservoir brackets andstraps, hydraulic,replacement:


Oil reservoir, hydraulic,maintenance:



Oil reservoir, winch hydraulic,replacement:


Oil seal (in vehicle), rear,maintenance:

Cleaning and inspection ...... 4-45b 4-298Installation ......................... 4-45c 4-298Removal.. ............................ 4-45a 4-298

Oil seal, front gearcase coverand, maintenance:

Cleaning and inspection ...... 4-48b 4-306Installation.. ....................... 4-48c 4-306Removal .............................. 4-48a 4-306

Oil seal, rear cover and,maintenance:

Cleaning and inspection ...... 4-44b 4-296Installation.. ....................... 4-44c 4-296Removal .............................. 4-44a 4-296

Oil seal, transmission outputshaft yoke and, replacement:


Oil section tube, oil pan and,maintenance:

Cleaning and inspection ...... 4-47c 4-304Oil pan installation ............ 4-47e 4-305Oil pan removal .................. 4-47a 4-304Oil suction tube 4-47d 4-304

installation.. .....................Oil suction tube removal ..... 4-47b 4-304

Oil service, transmission,instructions:

Draining oil.. ....................... 3-133a 3-354Governor filter

installation.. ..................... 3-133e 3-358Governor filter removal.. ..... 3-133d 3-358Oil filter installation.. ......... 3-133c 3-356Oil filter removal.. ............... 3-133b 3-356Replenishing oil .................. 3-133f 3-360

One-way check valve, airreservoir, replacement:


Operation reference index,principles of.. ........................ 1-19 1-25

Operation, general, principlesof .......................................... 1-18 1-25

Operation:Central tire inflation system

(CTIS) operation ............... 1-25 1-78Compressed air and brake

system.. ............................ 1-23 1-25Control system.. .................... 1-20 1-25Electrical systems.. ............... 1-22 1-45Hydraulic system .................. 1-24 1-71Power system.. ..................... 1-21 1-34

Outside door handlereplacement:


Outside telephone jack postreplacement:


Index 44

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

P

Packaging, general preparationof vehicle for shipment . . . . . . . . . . 6-5 6-2

Packing, general preparation ofvehicle for shipment.. ............ 6-6 6-2

Panel light and lamp, indicatorreplacement:

Lamp installation.. ............. 3-84d 3-246Lamp removal .................... 3-84c 3-246Light assembly installation. 3-84b 3-246Light assembly removal ...... 3-84a 3-246

Panel seals replacement:Installation.. ....................... 3-363b 3-904Removal.. ............................ 3-363a 3-904

Panel, exterior side,maintenance:


Panel, instrumentreplacement:


Panels, ceiling filler and side,replacement:


Panels, latches, side panelsand, replacement:

Installation.. ....................... 5-7513 5-504Removal.. ............................ 5-75a 5-500

Panels, rear wall interiorreplacement:


Parking and service brakedrumrepair:

Cleaning ............................. 4-110a 4-592Inspection ........................... 4-110b 4-592

Parking and service brakeshoerepair:

Inspection.. ......................... 4-111c 4-595Parking brakeshoe

assembly .......................... 4-111e 4-595Parking brakeshoe

disassembly ...................... 4-111a 4-594Service brakeshoe

assembly .......................... 4-111d 4-595Service brakeshoe

disassembly.. .................... 4-11 lb 4-594

Parking brake adjustment:Lever arm adjustment........ 3-172d 3-480Major adjustment . . . . . . . . . . . . . . . 3-172c 3-480Minor adjustment . . . . . . . . . . . . . . . 3-172b 3-478Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172a 3-478

Parking brake cable andbracket replacement:


Parking brake lever and switchreplacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-174b 3-484Removal . . . . . . . . . . . . . . . . . . . . . 3-174a 3-484

Parking brakedrum dustcoverreplacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-177b 3-494Removal . . . . . . . . . . . . . . . . . . . . . 3-177a 3-494

Parking brakeshoesreplacement:

Installation . . . . . . . . . . . . . . . . . 3-176b 3-492Removal . . . . . . . . . . . . . . . . . . . . . . 3-176a 3-490

Pedal, brake, maintenance:Adjustment . . . . . . . . . . . . . . . . . . . 3-196c 3-534Installation . . . . . . . . . . . . . . . . . . . . 3-196b 3-534Removal . . . . . . . . . . . . . . . . . . . . . . 3-196a 3-534

Personnel fuel burning heater(M939/A1) replacement:

Installation... . . . . . . . . . . . . . . . . . . . 4-215b 4-1004Removal ............................ 4-215a 4-1004

Personnel fuel burning heaterand mounting bracket(M939A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 4-217b 4-1008Removal . . . . . . . . . . . . . . . . . . . . . 4-217a 4-1008

Personnel fuel burning heatercircuit breaker replacement:


Personnel fuel burning heatercontrol box replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-214b 4-1003Removal.. . . . . . . . . . . . . . . . . . . . . . 4-214a 4-1002

Personnel fuel burning heaterelectric fuel pump (M939A2)replacement:


Personnel fuel burning heaterexhaust tube (M939/A1)replacement:


Index 45

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Personnel fuel burning heaterexhaust tube (M939A2)replacement:


Personnel fuel burning heaterfuel pump (M939/A1)replacement:


Personnel fuel burning heaterfuel shutoff valvereplacement:


Personnel fuel burning heatermounting bracket (M939/A1)replacement:


Personnel fuel burning heaterwiring harness replacement:


Personnel heater inlet andoutlet hose replacement:


Personnel hot water heaterreplacement:


Pintle hook maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . 3-242d 3-687Cleaning and inspection...... 3-242c 3-686Disassembly . . . . . . . . . . . . . . . . . . 3-242b 3-686Installation . . . . . . . . . . . . . . . . . . . . 3-242e 3-687Removal . . . . . . . . . . . . . . . . . . . . . . . 3-242a 3-686

Pioneer tool kit mountingbracket replacement:

Bracket installation (M923,M925, M927, M928) . . . . . . . . . 3-415b 3-1052

Bracket installation (M929,M930) . . . . . . . . . . . . . . . . . . . . . . 3-415f 3-1054

Bracket installation(M929A1, M930A1) . . . . . . . 3-415h 3-1054

Bracket installation (M931,M932). . . . . . . . . . . . . . . . . . . . . . . . . 3-415d 3-1052

Bracket removal (M923,M925, M927, M928) . . . . . . . . . 3-415a 3-1052

Bracket removal (M929,M930). . . . . . . . . . . . . . . . . . . . . . . . 3-415e 3-1054

Bracket removal (M929A1,M930A1) . . . . . . . . . . . . . . . . . . . . . 3-415g 3-1054

Bracket removal (M931,M932) . . . . . . . . . . . . . . . . . . . . . . . 3-415c 3-1052

Index 46

Pipe, front exhaust,replacement:

Installation.. .......................Removal.. .............................

Piston and connecting rodmaintenance:

Assembly.. ..........................Cleaning and inspection......Connecting rod side

clearance check .................Disassembly.. .....................Installation.. .......................Removal ..............................

Piston and connecting rodmaintenance:

Assembly ............................Cleaning and inspection......Disassembly.. .....................Installation.. .......................Removal ..............................

Piston, first clutch, adapterhousing, maintenance:

Assembly ............................Cleaning and inspection ......Disassembly.. .....................Removal ..............................

Pitman arm replacement(Ross):


Pitman arm replacement(Sheppard):


Pitman, arm, replacement(Ross):

Installation .........................Removal ..............................

Pitman, arm, replacement(Sheppard):


Planetary carrier, adapterhousing, low clutch, and rearcover, low, installation:

Installation.. .......................Planetary carrier, rear cover

and, maintenance:Assembly.. ..........................Cleaning and inspection......Disassembly.. .....................Removal ..............................

Platel, rear splice,replacement:


Para Page

3-50b 3-144.3-50a 3-144

5-10e 5-745-10d 5-68

5-10a 5-645-10c 5-685-10f 5-765-10b 5-66

5-26d 5-1705-26c 5-1685-26b 5-1665-26e 5-1725-26a 5-166

5-57d 5-3805-57c 5-3805-57b 5-3785-57a 5-378

3-227b 3-6533-227a 3-653

3-228b 3-6543-228a 3-654

3-227b 3-6533-227a 3-653

3-228b 3-6543-228a 3-654

5-58 5-382

5-55d 5-3705-55c 5-3685-55b 5-3665-55a 5-364

5-84b 5-5435-84a 5-543

TM 9-2320-272-24-4

Plates, front bumper and,replacement:

Para

INDEX

Page


Pneumatic controller and reliefvalve maintenance:


Power cable reel (M934A1/A2),van, replacement:


Power plant (M939/A1)replacement:

Installation.. ....................... 4-4c 4-53Preliminary disconnections. 4-4a 4-36Removal.. ............................ 4-4b 4-49

Power plant (M939A2)replacement:

Installation.. ....................... 4-5c 4-76Preliminary disconnections. 4-5a 4-67Removal.. ............................ 4-5b 4-75

Power steering gearadjustment (on-vehicle):

Sector shaft adjustment...... 4-125a 4-668Wormshaft adjustment....... 4-125b 4-668

Power steering pump(M939/A1) maintenance:

Assembly.. .......................... 3-236c 3-672Disassembly ....................... 3-236b 3-672Installation.. ....................... 3-236d 3-673Removal.. ............................ 3-236a 3-672

Power steering pump(M939A2) repair:


Power steering pump andreservoir (M939/A1) repair:


Power steering pump filter(M939A2) maintenance:

Cleaning.. ........................... 3-237c 3-674Filter installation.. ............. 3-237e 3-674Filter removal.. ................... 3-237a 3-674Reservoir installation.. ........ 3-237d 3-674Reservoir removal ............... 3-237b 3-674

(Contd)

Para Page

Power steering pump filter andreservoir (M939A2)maintenance:

Cleaning . . . . . . . . . . . . . . . . . . . . . . . 3-237c 3-674Filter installation . . . . . . . . . . . . . . . 3-237e 3-674Filter removal . . . . . . . . . . . . . . 3-237a 3-674Reservoir installation . . . . . . . . . . 3-237d 3-674Reservoir removal . . . . . . . . . . . . . 3-237b 3-674

Power steering pumpmaintenance:

Assembly . . . . . . . . . . . . . . . . . . 3-236c 3-673Disassembly . . . . . . . . . . . . . . . . . . . 3-236b 3-672Installation . . . . . . . . . . . . . . . . . . . . . 3-236d 3-673Removal . . . . . . . . . . . . . . . . . . . . . . . 3-236a 3-672

Power steering pump pressureand return hoses replacement(Ross):


Power steering pump pressureand return hoses replacement(Sheppard):


Power steering pump testequipment setup:

Installation . . . . . . . . . . . . . . . . . . . . . 4-122a 4-658Removal . . . . . . . . . . . . . . . . . . . . . . . 4-122b 4-658

Power steering tests andadjustment (Ross):

Poppet adjustment . . . . . . . . . . . . . 4-123d 4-662Steering gear internal

leakage test . . . . . . . . . . . . . . . . . . 4-123c 4-662Steering pump flow test...... 4-123b 4-661Steering pump pressure

test.............................. 4-123a 4-660Power steering tests and

adjustment (Sheppard):Plunger adjustment . . . . . . . . . . . . 4-124d 4-666Steering gear internal

leakage test . . . . . . . . . . . . . . . . . . . 4-124c 4-664Steering pump flow test . . . . . . 4-124b 4-664Steering pump pressure

test . . . . . . . . . . . . . . . . . . . . . . . . 4-124a 4-664Power system operation . . . . . . . . . . 1-21 1-34Power Takeoff (PTO) control

cable (M939A2),transmission, replacement:


Power Takeoff (PTO) controlcable, transmission,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 4-209b 4-976Removal . . . . . . . . . . . . . . . . . . . . . . 4-209a 4-976

Index 47

TM 9-2320-272-24-4

INDEX

Para Page

Power Takeoff (PTO) cross-shaft (control lever), transfercase, replacement:


Power Takeoff (PTO), transfercase, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . 4-208c 4-970Cleaning and inspection...... 4-208b 4-968Disassembly . . . . . . . . . . . . . . . . . . . 4-208a 4-962

Power Takeoff (PTO), transfercase, replacement:

Installation .. . . . . . . . . . . . . . . . . . . . 4-207b 4-960Removal . . . . . . . . . . . . . . . . . . . . . . . 4-207a 4-958

Power Takeoff (PTO),transmission, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . 4-212c 4-996Cleaning and inspection...... 4-212b 4-994Disassembly . . . . . . . . . . . . . . . . . . 4-212a 4-988

Power Takeoff (PTO),transmission, replacement:


Preparation for storage orshipment . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-2

Preparing replacement enginefor installation in vehicle:

Installation . . . . . . . . . . . . . . . . . . 4-7b 4-92Removal . . . . . . . . . . . . . . . . . . . . . . . 4-7a 4-91

Preservation, generalpreparation of vehicle forshipment . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6-2

Pressure gear pump removal:Removal . . . . . . . . . . . . . . . . . . . . . . 5-13 5-93

Pressure lines, steering gear-to-assist cylinderreplacement:

Installation. . . . . . . . . . . . . . . . . . . . . 3-239b 3-680Removal . . . . . . . . . . . . . . . . . . . . . . . 3-239a 3-678

Pressure relief valvemaintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . 3-389b 3-956Testing . . . . . . . . . . . . . . . . . . . . . . . . . 3-389a 3-956

Pressure switch replacement:Installation . . . . . . . . . . . . . . . . . . . . 3-467b 3-1280Removal . . . . . . . . . . . . . . . . . . . . . . . 3-467a 3-1280

Pressure switch, 5th gear lock-up, transmissionreplacement:


Pressure switch, spring brake,replacement:


Index 48

(Contd)

Para Page

Pressure transducerreplacement:


Preventive MaintenanceChecks and Services (PMCS),unit:

General . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-2Intervals . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-2Reporting repairs . . . . . . . . . . . . . . 2-10 2-3General service and

inspection procedures.. . . . . . . 2-11 2-3Specific PMCS procedures. . . 2-12 2-3

Primary air reservoir (supplytank) replacement:


Primary and secondary low airpressure switch replacement:

Primary switchinstallation . . . . . . . . . . . . . . . . . . 3-99b 3-274

Primary switchremoval . . . . . . . . . . . . . . . . . . . . . . 3-99a 3-274

Secondary switchinstallation . . . . . . . . . . . . . . . . . . . 3-99d 3-276

Secondary switchremoval . . . . . . . . . . . . . . . . . . . . . . 3-99c 3-276

Primary, air reservoir (supplytank), replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-202b 3-564Removal........................... 3-202a 3-562

Primer pump (M939/A1), fuel,replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-40b 3-122Removal . . . . . . . . . . . . . . . . . . . . . . 3-40a 3-122

Priming fuel system (M939A2):Priming............................... 3-22 3-72

Principles of operationreference index . . . . . . . . . . . . . . . . . 1-19 1-25

Principles of operation, general 1-18 1-25Propeller shaft, forward-rear to

rear-rear, replacement:Installation . . . . . . . . . . . . . . . . . . . . 3-151b 3-420Removal . . . . . . . . . . . . . . . . . . . . . . 3-151a 3-420

Propeller shaft, PTO-to-hydraulic pump,transmission, replacement:


Propeller shaft, transfer caseto forward-rear axle,maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . 3-150d 3-416

INDEX

Para Page

Cleaning and inspection...... 3-150c 3-414Disassembly.. ..................... 3-150b 3-414Installation.. ....................... 3-150e 3-416Removal.. ............................ 3-150a 3-412

Propeller shaft, transfer case-to-front axle, replacement:


Propeller shaft, transmission-to-transfer case,maintenance:

Assembly ............................ 3-148c 3-408Disassembly.. ..................... 3-148b 3-408Installation.. ....................... 3-148d 3-408Removal.. ............................ 3-148a 3-406

Proportioning valve, brake,replacement:


Protective control boxreplacement:


PTO-to-hydraulic pumppropeller shaft, transfer,replacement:


Pulley (M939/A1), alternator,replacement:


Pulse sensor (M939/A1),tachometer replacement:


Pulse sensor (M939A2),tachometer replacement:


Pump (M939/A1), powersteering, maintenance:

Assembly.. .......................... 3-236c 3-672Disassembly.. ..................... 3-236b 3-672Installation.. ....................... 3-236d 3-673Removal.............................. 3-236a 3-672

Pump (M939/A1), watermaintenance:

Assembly ............................ 4-63c 4-384Cleaning and inspection ...... 4-63b 4-381Disassembly.. ..................... 4-63a 4-378

Pump (M939/A1), water,replacement:


TM 9-2320-272-24-4

(Contd)

Para Page

Pump (M939A2), powersteering, repair:


Pump (M939A2), water,maintenance:


Pump, engine oil, repair:Assembly.. .......................... 5-11d 5-88Cleaning and inspection ...... 5-11b 5-84Disassembly.. ..................... 5-11a 5-78Repair.. ............................... 5-11c 5-86

Pump, fuel injection,calibration:

Cylinder phasing (timing).... 5-37b 5-266External stop setting.. ........ 5-37mFuel breakaway test.. 5-37j

5-2785-277.........

Fuel delivery test.. .............. 5-37i 5-276Full load delivery.. .............. 5-37g 5-274High-speed fuel delivery

test ................................... 5-37d 5-270Lock timing.. ....................... 5-37c 5-268Low idle fuel delivery test ... 5-371 5-278Low-speed fuel delivery

test.. ................................. 5-37e 5-270Manifold pressure

compensator test.. ............ 5-37h 5-275Prestroke and rack

travel.. .............................. 5-37a 5-262Rated speed test.. ............... 5-37f 5-272Starting fuel delivery test.... 5-37k 5-277

Pump, fuel injection,maintenance:

Barrel and control rackremoval.. ........................... 5-36c 5-246

Camshaft installation.. ....... 5-36i 5-258Camshaft removal .............. 5-36a 5-240Cleaning and inspection ...... 5-36d 5-248Delivery valve and

barrel installation.. ........... 5-36f 5-252Leakage test.. ..................... 5-36e 5-250Plunger and control rack

installation.. ..................... 5-36g 5-254Tappet and plunger

removal.. ........................... 5-36b 5-244Tappet and spring

installation.. ..................... 5-36h 5-256Pump, fuel injection, pretest:

Cylinder phasing (timing).... 5-32b 5-216Fuel breakaway test.. ......... 5-32j 5-222Fuel delivery test.. .............. 5-323 5-220Full load delivery.. .............. 5-32f 5-220

Index 49

TM 9-2320-272-24-4

INDEX (Contd)Para Page Para Page

High-speed fuel deliverytest.. ................................. 5-32c 5-218

Low idle fuel delivery test ... 5-321 5-222Low speed fuel delivery

test.. ................................. 5-32d 5-218Manifold pressure

compensator test.. ............ 5-32g 5-220Prestroke and racktravel.. .............................. 5-32a 5-214

Rated speed test.. ............... 5-32e 5-218Starting cut out test.. .......... 5-32h 5-220Starting fuel delivery test.... 5-32k 5-222

Pump, fuel, replacement:Installation.. ....................... 4-35b 4-262On-engine adjustments ....... 4-35c 4-264Removal.. ............................ 4-35a 4-260

Pump, oil, maintenance:Cleaning and inspection...... 4-49c 4-310Gear backlash test.. ........... 4-49a 4-308Installation.. ....................... 4-49d 4-310Removal.. ............................ 4-49b 4-308

Pump, pressure gear, removal:Removal.............................. 5-13 5-93

Pump, steering, drivebelts,maintenance (M939/A1):Adjustment.. ....................... 3-230b 3-656Inspection.. ......................... 3-230c 3-656Installation.. ....................... 3-230d 3-657Removal.............................. 3-230a 3-656

Pump, swingtire heater,replacement:


Pump, transfer case oil,replacement:


Pump, water, maintenance:Assembly.. .......................... 4-29d 4-206Cleaning and inspection...... 4-29c 4-204Disassembly.. ..................... 4-29b 4-202Installation.. ....................... 4-29e 4-208Removal.. ............................ 4-29a 4-200

Pump, wrecker crane hydraulic,replacement:


Push rods, rocker levers and,maintenance:


Push tubes, rocker leverhousing and, maintenance:

Assembly.... . . . . . . . . . . . . . . . . .Cleaning and inspection......Disassembly . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . .

Pushrods, rocker levers,cylinder head and,replacement:

Cylinder head installation ..Cylinder head removal . . . . . .Rocker levers and push

rods installation . . . . . . . . . . . . .Rocker levers and push

rods removal . . . . . . . . . . . . . . . . . . . . .

4-20d 4-1604-20c 4-1564-20b 4-1564-20e 4-1604-20a 4-154

4-41c 4-2864-41b 4-282

4-41d 4-289

4-41a 4-280

R

R.Q.V. governor covermaintenance:

Adjustment .........................Assembly.. ..........................Cleaning and


R.Q.V. governor housingmaintenance:

Adjustment.. .......................Assembly.. ..........................Cleaning and


Radiator (M9391A1)replacement:


Radiator (M939A2)maintenance:

Cleaning and inspection ......Installation.. .......................Removal.. ............................

Radiator baffles, seals, andplates replacement:

Installation .........................Removal ..............................

Radiator brushguardmaintenance:

Inspection and repair.. ........Installation.. .......................Removal ..............................

5-34e 5-2305-34d 5-230

5-34c 5-2285-34b 5-2285-34f 5-2305-34a 5-228

5-35f 5-2385-35d 5-234

5-35c 5-2345-35b 5-2345-35c 5-2365-35a 5-232

3-59b 3-1743-59a 3-172

3-60b 3-1773-60c 3-1783-60a 3-176

3-272b 3-7383-272a 3-738

4-136b 4-7024-136c 4-7044-136a 4-700

Index 50

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Radiator cover kit replacement:Installation.. ....................... 3-395b 3-970Removal.. ............................ 3-395a 3-970

Radiator fan blade (M939/A1)replacement:


Radiator fan shroud (M939/A1)replacement:


Radiator hoses and brackets(M939A2), upper,replacement:


Radiator maintenance:Assembly.. .......................... 4-60c 4-354Cleaning, inspection, and

repair.. .............................. 4-60b 4-354Disassembly.. ..................... 4-60a 4-352

Radiator vent hose, manifoldreturn hose, and surge tank,(M939/A1) replacement:

Radiator vent and manifoldreturn hoses installation ... 3-61d 3-182

Radiator vent and manifoldreturn hoses removal ........ 3-61a 3-180

Surge tank installation ....... 3-61c 3-182Surge tank removal.. ........... 3-6 lb 3-180

Rail sill, cargo body frame,maintenance:

Fabrication.. ....................... 4-143c 4-723Inspection.. ......................... 4-143b 4-722Installation.. ....................... 4-143d 4-725Removal.. ............................ 4-143a 4-722

Rear axle air manifoldmaintenance:


Rear axle shaft maintenance:Inspection.. ......................... 3-157b 3-433Installation.. ....................... 3-157c 3-433Removal.. ............................ 3-157a 3-433

Rear axles spring seat wearpads and upper bracketmaintenance:


Rear brake actuator repair:Assembly.. .......................... 4-113c 4-602Cleaning and inspection ...... 4-113b 4-600Disassembly.. ..................... 4-113a 4-600

Rear brake spiderreplacement:


Rear cab mount replacement:Installation.. .......................Removal.. ............................

Rear cover and low planetarycarrier maintenance:

Assembly.. ..........................Cleaning and inspection ......Disassembly.. .....................Removal ..............................

Rear cover and oil sealmaintenance:

Cleaning and inspection ......Installation.. .......................Removal ..............................

Rear differential oil sealreplacement:


Rear door maintenance:Assembly ............................Cleaning and inspection ......Disassembly.. .....................Installation.. .......................Removal ..............................

Rear exhaust pipe, supportbracket, and cab heat shieldmaintenance:

Inspection.. .........................Installation.. .......................Removal ..............................

Rear hub and drum (M939/A1)maintenance:

Cleaning and inspection ......Installation.. .......................Lubrication.. .......................Removal.. ............................

Rear hubs repair:Cleaning and inspection ......Installation.. .......................Removal ..............................Repair.. ...............................

Rear oil seal (in vehicle)maintenance:

Cleaning and inspection ......Installation.. .......................Removal., ............................

Rear relay valve replacement:Installation.. .......................Removal ..............................

Rear splice plate replacement:Installation.. .......................Removal ..............................

Para Page

3-184b 3-5103-184a 3-510

3-305b 3-8023-305a 3-802

5-55d 5-3705-55c 5-3685-55b 5-3665-55a 5-364

4-44b 4-2964-44c 4-2964-44a 4-296

4-103b 4-5764-103a 4-576

4-154d 4-7584-154c 4-7584-154b 4-7564-154e 4-7604-154a 4-756

3-49b 3-1423-49c 3-1423-49a 3-142

3-224b 3-6443-224d 3-6463-224c 3-6443-224a 3-642

3-461b 3-12603-461d 3-12623-461a 3-12583-461c 3-1260

4-45b 4-2984-45c 4-2984-45a 4-298

3-188b 3-5183-188a 3-518

5-84b 5-5435-84a 5-543

Index 51

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Rear spring bumperreplacement:


Rear spring replacement:Installation.. ....................... 3-167b 3-458Removal.. ............................ 3-167a 3-454

Rear spring seat maintenance:Adjustment.. ....................... 3-169e 3-466Cleaning and inspection ...... 3-169b 3-464Installation.. ....................... 3-169d 3-466Lubrication.. ....................... 3-169c 3-466Removal.. ............................ 3-169a 3-464

Rear wall interior panelsreplacement:


Rear wheel valve maintenance:Cleaning and inspection...... 3-457b 3-1246Installation.. ....................... 3-457c 3-1247Removal.. ............................ 3-457a 3-1246

Rear winch adjustment:Cable tensioner

adjustment.. ..................... 3-330b 3-844Cable tensioner

check.. ............................... 3-330a 3-844Rear winch cable replacement:


Rear winch cable tensionerrepair:



Rear winch hydraulic motorreplacement:


Rear winch repair:Assembly.. .......................... 4-181c 4-872Cleaning and inspection...... 4-181b 4-870Disassembly.. ..................... 4-181a 4-864

Rear winch replacement:Installation.. ....................... 3-332b 3-848Removal.. ............................ 3-332a 3-847

Rear winch roller repair:Cleaning and inspection ...... 4-153c 5-754Side roller assembly.. .......... 4-153e 4-754Side roller disassembly ....... 4-153a 4-752Top and bottom roller

assembly.. ........................ 4-153d 4-754Top and bottom roller

disassembly.. .................... 4-153b 4-752

Para Page

Rear winch side roller repair:Assembly.. .......................... 4-183c 4-885Cleaning and inspection ...... 4-183b 4-884Disassembly.. ..................... 4-183a 4-884

Rear winch top and bottomroller repair:


Rear wiring harnessreplacement:


Rear, axle, shaft, maintenance:Inspection.. ......................... 3-157b 3-433Installation.. ....................... 3-157c 3-433Removal.. ............................ 3-157a 3-433

Rearview mirror and bracereplacement:


Receptacle (M936/A1/A2),auxiliary outlet socket and,replacement:


Receptacle 220v 3-phase wiringharness, entrance,maintenance:


Receptacle 220v 3-phase wiringharness, entrance,maintenance:

Installation.. ....................... 4-159c 4-772Removal.. ............................ 4-159a 4-772Repair................................. 4-159b 4-772

Receptacle, slave, replacement:Installation.. ....................... 3-127b 3-340Removal.. ............................ 3-127a 3-340

Reflectors replacement:Installation.. ....................... 3-345b 3-879Removal.. ............................ 3-345a 3-879

Registers, front wall,replacement:


Relay valve repair:Assembly.. .......................... 4-109c 4-590Cleaning and inspection...... 4-109b 4-590Disassembly.. ..................... 4-109a 4-590

Relay valve, front,replacement:


Index 52

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Relay valve, rear, replacement:Installation.. ....................... 3-188b 3-518Removal.. ............................ 3-188a 3-518

Relief safety valvemaintenance:


Removal from limited storage. 6-12 6-3Repair, general.. ..................... 2-16 2-57Reporting Equipment

ImprovementRecommendations (EIRs);reporting of errors andrecommendingimprovements.. ..................... 1-6 1-2

Reservoif shutoff modificationkit, hydraulic, replacement:

Installation.. ....................... 3-445b 3-1156Removal.. ............................ 3-4453 3-1154

Reservoir (M939/A1), powersteering pump and, repair:Assembly ............................ 4-126d 4-672

...... 4-126c 4-672Cleaning and inspectionDisassembly.. ..................... 4-126b 4-670Installation.. ....................... 4-126e 4-672Removal.. ............................ 4-126a 4-670

Reservoir (supply tank) andbracket, wet air, replacement:


Reservoir (supply tank) andmounting plate, wet air,(M936/A1/A2) replacement:


Reservoir, jet, and control,windshield wiper,replacement:


Resistor, convoy warning light,leads and, replacement:


Retaining bracket, hood,replacement:


Retaining straps, fuel tankhangers and, maintenance:


Retractable beam drive shaftand lock maintenance:

Cleaning, inspection,and repair.. ....................... 5-68b 5-472


Retractable beam replacement:Installation.. ....................... 5-67b 5-468Removal.. ............................ 5-67a 5-468

Retractable beam rollersreplacement:

End roller installation.. ....... 5-69d 5-476End roller removal .............. 5-69c 5-476Support roller installation ... 5-69b 5-474Support roller removal ........ 5-69a 5-474

Retractable window glass andvan door window glassreplacement:


Retractable window regulatorreplacement:


Retractable windowreplacement:


Return tubes (M939/A1), aircompressor coolant supplyand, maintenance:

Inspection.. ......................... 3-55c 3-161Return tube installation ..... 3-55e 3-163Return tube removal.. ......... 3-55b 3-161Supply tube installation.. ... 3-55d 3-162Supply tube removal.. ......... 3-55a 3-160

Rifle mounting kit replacement:Installation on left door.. .... 3-421c 3-1082Installation on dash

and floor.. ......................... 3-421d 3-1083Removal from dash

and floor.. ......................... 3-421b 3-1081Removal from left door ........ 3-421a 3-1080

Right and left side blackoutharness maintenance:


Right and left side blackoutharness maintenance:


Index 53

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Ring gear, flywheel,maintenance:


Rocker lever housing and pushtubes maintenance:


Rocker levers and push rodsmaintenance:


Rocker levers, push rods, andcylinder head replacement:

Cylinder head installation.. 4-41c 4-286Cylinder head removal ........ 4-41b 4-282Rocker levers and push

rods installation.. ............. 4-41d 4-289Rocker levers and push

rods removal.. ................... 4-41a 4-280Rod, connecting, piston, and,

maintenance:Assembly.. .......................... 5-26d 5-170Cleaning and inspection ...... 5-26c 5-168Disassembly.. ..................... 5-26b 5-166Installation.. ....................... 5-26e 5-172Removal.. ............................ 5-26a 5-166

Rod, piston and connecting,maintenance:

Assembly.. .......................... 5-10e 5-74Cleaning and inspection...... 5-10d 5-68Connecting rod side

clearance check ................. 5-10a 5-64Disassembly.. ..................... 5-10c 5-68Installation.. ....................... 5-10f 5-76Removal.. ............................ 5-10b 5-66

Rod, stopscrew, acceleratorpedal, bracket and,replacement:


Rod, tie, maintenance:Inspection.. ......................... 3-153b 3-424Installation.. ....................... 3-153c 3-424Removal.. ............................ 3-153a 3-424

Roller, boom, maintenance:Assembly.. .......................... 4-197d 4-924Cleaning and inspection ...... 4-197c 4-924Disassembly.. ..................... 4-197b 4-922Installation.. ....................... 4-197e 4-924Removal.. ............................ 4-197a 4-922

Index 54

Para Page

Roof, hinged, maintenance:Assembly.. .......................... 5-77d 5-526Cleaning and inspection...... 5-77c 5-524Disassembly.. ..................... 5-77b 5-520Installation.. ....................... 5-77e 5-530Removal.. ............................ 5-77a 5-518

Rotation, wheel and, tire(M939):

Front wheel installation.. ... 3-218f 3-621Inner rear wheel

installation.. ..................... 3-218d 3-619Wheel and tire removal ....... 3-218b 3-616Inspection.. ......................... 3-218e 3-620Outer rear wheel

installation.. ..................... 3-218a 3-616Wheel and tire rotation....... 3-218c 3-618

Rotation, wheel and, tire(M939A1/A2):

Front wheel installation.. ... 3-219e 3-625Inspection.. ......................... 3-219b 3-622Rear wheel installation....... 3-219d 3-624Wheel and tire removal ....... 3-219a 3-622Wheel and tire rotation....... 3-219c 3-624

S

Safety valve, wet reservoir(supply tank), replacement:


Scope.. .................................... 1-1 1-1Scope, general preparation of

vehicle for shipment.. ............ 6-1 6-1Scope, limited storage.. ........... 6-9 6-2Screen, window, replacement:


Seal and retainer, cab top,replacement:


Seal, front, axle, replacement:Installation.. ....................... 3-160b 3-439Removal.. ............................ 3-160a 3-439

Seals, panel, replacement:Installation.. ....................... 3-363b 3-904Removal.. ............................ 3-363a 3-904

Seat frame and base, driver’s,maintenance:


Seat, driver’s, replacement:Installation.. ....................... 3-283b 3-762Removal.. ............................ 3-283a 3-762

INDEX

Para Page

Seatbelt replacement:Companion seatbelts

installation . . . . . . . . . . . . . . . . . . 3-289d 3-776Companion seatbelts

removal . . . . . . . . . . . . . . . . . . . . 3-289c 3-776Driver’s seatbelt

installation . . . . . . . . . . . . . . . . . . 3-289b 3-774Driver’s seatbelt

removal . . . . . . . . . . . . . . . . . . . . . . . 3-289a 3-774Second clutch maintenance:

Cleaning and inspection...... 5-52b 5-354Establishing clearance........ 5-52d 5-356Installation . . . . . . . . . . . . . . . . . . . . 5-52c 5-356Removal . . . . . . . . . . . . . . . . . . . . . . . 5-52a 5-354

Secondary air reservoir (supplytank) replacement:


Secondary low air pressureswitch, primary and,replacement:

Primary switchinstallation . . . . . . . . . . . . . . . . . . . 3-99b 3-274

Primary switchremoval . . . . . . . . . . . . . . . . . . . . . . . 3-99a 3-274

Secondary switchinstallation . . . . . . . . . . . . . . . . . . . 3-99d 3-276

Secondary switchremoval . . . . . . . . . . . . . . . . . . . . 3-99c 3-276

Secondary, air reservoir (supplytank), replacement:


Select lever, transmission,replacement:


Selector switch, high-beam,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-112b 3-301Removal . . . . . . . . . . . . . . . . . . . . . . 3-112a 3-301

Sending unit, fuel level,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-92b 3-264Removal . . . . . . . . . . . . . . . . . . . . . 3-92a 3-264

Sending unit, oil pressure,replacement:


Sending unit, watertemperature, replacement:


TM 9-2320-272-24-4

(Contd)

Para Page

Separator, water,maintenance:

Assembly.. .......................... 3-466d 3-1278Cleaning and inspection ...... 3-466c 3-1278Disassembly.. ..................... 3-466b 3-1278Installation.. ....................... 3-466e 3-1279Removal.............................. 3-466a 3-1278

Service brake chamberreplacement:


Service brake chamber,combination spring(emergency) and,replacement:

Installation. ........................ 3-182b 3-506Removal.. ............................ 3-182a 3-506

Service upon receipt, general ... 2-5 2-1Shackle, front spring,


Shaft oil seal, transmissionselector, replacement:


Shaft, rear, axle, maintenance:Inspection.. ......................... 3-157b 3-433Installation.. ....................... 3-157c 3-433Removal.. ............................ 3-157a 3-433

Shaft, throttle cover and,maintenance:

Assembly.. .......................... 5-16c 5-100Disassembly.. ..................... 5-16a 5-98Inspection.. ......................... 5-16b 5-98

Shield, muffler and,maintenance:

Inspection ........................... 3-51b 3-146Installation.. ....................... 3-51c 3-146Removal.. ............................ 3-51a 3-146

Shift cable, transmission,maintenance:


Shift lever shift rod, transfercase, maintenance:

Adjustment.. ....................... 4-86b 4-512Installation.. ....................... 4-86c 4-512Removal.. ............................ 4-86a 4-512

Shift lever, dump valve cableand, replacement:

Installation andadjustment.. ..................... 4-148b 4-740

Removal .............................. 4-148a 4-738

Index 55

TM 9-2320-272-24-4

INDEX (Contd)

Shift lever, transfer case,maintenance:

Para Page

Cleaning, inspection, andrepair . . . . . . . . . . . . . . . . . . . . . . . 4-85b 4-510

Installation . . . . . . . . . . . . . . . . . . . . 4-85c 4-510Removal . . . . . . . . . . . . . . . . . . . . . . . 4-85a 4-510

Shift rod, transfer case,maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . 4-88c 4-517Cleaning, inspection, and

repair a............................... 4-88b 4-516Installation . . . . . . . . . . . . . . . . . . . . . 4-88d 4-517Removal . . . . . . . . . . . . . . . . . . . . . . . 4-88a 4-516

Shift tower, transmission,replacement:


Shipment of Armydocuments . . . . . . . . . . . . . . . . . . . . . . 6-7 6-2

Shock absorber and mountingpins replacement:


Shroud (M939/A1), radiatorfan, replacement:

Installation...................... 3-63b 3-186Removal . . . . . . . . . . . . . . . . . . . . . . . 3-63a 3-186

Shutoff valve (M936), fuelpump, replacement:


Shutoff valve, fuel pump,replacement:

Fuel pump shutoff valveinstallation . . . . . . . . . . . . . . . . . . . 4-36c 4-266

Fuel pump shutoff valveremoval . . . . . . . . . . . . . . . . . . . . . . . 4-36b 4-266

Manual shutoff valveinstallation . . . . . . . . . . . . . . . . . . . 4-36d 4-266

Manual shutoff valveremoval . . . . . . . . . . . . . . . . . . . . . . . 4-36a 4-266

Side and rear door blackoutlight switch maintenance:


Side cover gasket, carrierdifferential top cover gasketand, replacement:

Side cover gasketinstallation . . . . . . . . . . . . . . . . . . . 3-158d 3-437

Side cover gasket removal... 3-158c 3-437Top cover gasketinstallation . . . . . . . . . . . . . . . . . . . 3-158b 3-436

Top cover gasket removal.... 3-158a 3-434

Index 56

Para Page

Side doors maintenance:Assembly ............................ 5-70d 5-480Cleaning and inspection...... 5-70c 5-480Disassembly.. ..................... 5-70b 5-480Installation.. ....................... 5-70e 5-482Removal .............................. 5-70a 5-478

Side locking pin retaining clipreplacement:


Side marker lights and bracketreplacement:

Lamp installation.. ............. 3-122d 3-330Lamp removal .................... 3-122a 3-330Light installation.. .............. 3-122c 3-330Light removal ..................... 3-122b 3-330

Side panel exterior lockreplacement:


Side panel front lock andhinged-type roof lockreplacement:


Side panel rear lockreplacement:


Side panel roof swivel hookreplacement:


Side panel rubber bumpersreplacement:


Side panel-to-roof toggle clampreplacement:


Slave receptacle replacement:Installation.. ....................... 3-127b 3-340Removal.. ............................ 3-127a 3-340

Sleeve, fuel injector,maintenance:

Bead cutting ....................... 5-6b 5-28Check and test.. .................. 5-6e 5-32Fitting and forming.. ........... 5-6d 5-30Installation.. ....................... 5-6c 5-28Removal.. ............................ 5-6a 5-26

Snubber valve assemblyreplacement:


INDEX

Para Page

Solenoid (M939A2), throttlecontrol, replacement:


Solenoid, bracket, horn and,replacement:


Solenoid, transmission fifthgear lock-in, replacement:

Installation..................... 4-80b 4-502Removal . . . . . . . . . . . . . . . . . . . . . . 4-80a 4-500

Spacers, fifth wheel,replacement:


Spare tire carrier (M923,M925, M927, M928), cargo,replacement:


Spare tire carrier(M923A1/A2,M925A1/A2,M927A1/A2, M928A1/A2),cargo, replacement:


Spare tire carrier (M929,M930), dump, replacement:


Spare tire carrier (M929A1/A2,M930A1/A2), dump,replacement:


Spare tire carrier (M931,M932), tractor, replacement:


Spare tire carrier (M931A1/A2,M932A1/A2), tractor,replacement:


Spare tire carrier (M934), van,replacement . . . . . . . . . . . . . . . . . . . 3-262 3-722

Spare tire carrier (M934A1/A2),van, replacement:


Specific inspection andservicing instructions . . . . . . . . . . . . 2-7 2-2

TM 9-2320-272-24-4

(Contd)

Speed signal generatorreplacement:

Para Page


Speedometer and tachometerreplacement:


Speedometer driveshaftmaintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . 3-90b 3-260Installation. . . . . . . . . . . . . . . . . . . . . 3-90c 3-260Removal . . . . . . . . . . . . . . . . . . . . . . . 3-90a 3-258

Spindle bearing sleevereplacement:


Splash guard, cargo upper andlower wheel, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-342b 3-874Removal........................... 3-342a 3-874

Splash shield, fender,replacement:


Spout, fuel tank, filler cap and,replacement:


Spray pattern test, injector:Setting up spray

pattern tester . . . . . . . . . . . . . . . . . 5-21a 5-140Testing spray pattern . . . . . . . . . 5-21b 5-140

Spring (emergency) and servicebrake chamber, combination,replacement:


Spring (emergency) brakechamber maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . 3-193c 3-528Disassembly . . . . . . . . . . . . . . . . . . . 3-193a 3-528Inspection . . . . . . . . . . . . . . . . . . . . . . 3-193b 3-528

Spring and main leaf, front,replacement:

Front spring main leafinstallation . . . . . . . . . . . . . . . . . . . . 3-161c 3-443

Front spring main leafremoval . . . . . . . . . . . . . . . . . . . . . . 3-161b 3-443

Front spring installation..... 3-161d 3-444Front spring removal . . . . . . . . . . 3-161a 3-440

Spring brake (supply tank),emergency, air reservoir,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-204b 3-570Removal............................ 3-204a 3-570

Index 57

TM 9-2320-272-24-4

INDEX

Para Page

Spring brake dash controlvalve replacement:


Spring brake pressure switchreplacement:


Spring brake valvemaintenance:


Spring bumper, front,replacement:


Spring bumper, rear,replacement:


Spring bushing, front,maintenance:

Inspection.. ......................... 3-163a 3-448Installation.. ....................... 3-163c 3-448Removal.. ............................ 3-163b 3-448

Spring pack, governor,maintenance:


Spring parking brake valvereplacement:


Spring seat wear pads andupper bracket, rear axles,maintenance:


Spring seat, rear,maintenance:

Adjustment.. ....................... 3-169e 3-466Cleaning and inspection ...... 3-169b 3-464Installation.. ....................... 3-169d 3-466Lubrication.. ....................... 3-169c 3-466Removal.. ............................ 3-169a 3-464

Spring shackle, front,replacement:


Spring, rear, replacement:Installation.. ....................... 3-167b 3-458Removal.. ............................ 3-167a 3-454

Index 58

(Contd)

Para Page

Stack, exhaust, replacement:Installation.. ....................... 3-48b 3-140Removal.. ............................ 3-48a 3-140

Stall test, transmissionconverter:

Forward stall test.. ............. 5-62 5-396Start switch, ether,

replacement:Installation ......................... 3-33b 3-112Removal.. ............................ 3-33a 3-112

Starter replacement:Installation.. ....................... 3-82b 3-236Removal.. ............................ 3-82a 3-234

Starting repaired orreplacement engine:

In-chassis run-in.. ............... 4-8c 4-96Out-of-chassis run-in

(M939/A1) ........................ 4-8b 4-96Priming lubrication

system (M939/A1). ............ 4-8a 4-95STE/ICE troubleshooting.. ...... 2-24 2-219Steering assist cylinder hoses


Steering assist cylinderreplacement:

Assembly.. .......................... 3-233c 3-664Disassembly.. ..................... 3-233b 3-664Installation.. ....................... 3-233d 3-666Removal.. ............................ 3-233a 3-662Travel adjustment.. ............ 3-233e 3-666

Steering assist cylinder stoneshield replacement:


Steering column, upper andlower, maintenance:

Cleaning, inspection,and repair.. ....................... 4-116c 4-608

Disassembly.. ..................... 4-116b 4-608Installation.. ....................... 4-116e 4-612Reassembly.. ...................... 4-116d 4-610Removal.. ............................ 4-116a 4-606

Steering gear (Ross) andmounting bracketreplacement:


Steering gear (Ross) repair:Assembly.. .......................... 4-119c 4-631Cleaning, inspection

and repair.. ....................... 4-119b 4-630Disassembly.. ..................... 4-119a 4-624Final adjustment.. .............. 4-119d 4-638

INDEX

Para Page

Steering gear (Sheppard) andmounting bracketreplacement:


Steering gear (Sheppard)repair:



Steering gear stone shieldreplacement:


Steering gear-to-assist cylinderpressure lines replacement:


Steering knuckle bootmaintenance:


Steering knuckle maintenance:Cleaning and inspection ...... 4-98b 4-552End play test.. .................... 4-98d 4-556Installation.. ....................... 4-98c 4-554Removal.. ............................ 4-98a 4-550

Steering pump drivebeltsmaintenance (M939/Al):

Adjustment.. ....................... 3-230b 3-656Inspection.. ......................... 3-230c 3-656Installation.. ....................... 3-230d 3-657Removal.. ............................ 3-230a 3-656

Steering stop adjustment:Check.. ................................ 4-105a 4-580Turning angle adjustment.. 4-105b 4-580

Steering wheel replacement:Installation.. ....................... 3-226b 3-652Removal .............................. 3-226a 3-651

Steering, assist cylinder,replacement:

Assembly.. .......................... 3-233c 3-664Disassembly.. ..................... 3-233b 3-664Installation.. ....................... 3-233d 3-666Removal.. ............................ 3-233a 3-662Travel adjustment.. ............ 3-233e 3-666

Step, tailgate personnel,replacement:


Steps, toolbox and,replacement:

Installation.. ....................... 3-302b 3-796Removal.. ............................ 3-302n 3-796

TM 9-2320-272-24-4

(Contd)

Para Page

Stone shield, steering assistcylinder, replacement:


Stone shield, steering gear,replacement:


Stop bracket and latch,windshield, replacement:


Stop cables, hood, replacement:Installation . . . . . . . . . . . . . . . . . . . . . 3-270b 3-736Removal......................... 3-270a 3-736

Stop control cable, emergency,maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-44b 3-132Installation . . . . . . . . . . . . . . . . . . . . . 3-44c 3-132Removal . . . . . . . . . . . . . . . . . . . . . . . 3-44a 3-130

Stop, steering, adjustment::Check . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105a 4-580Turning angle adjustment.. 4-105b 4-580

Stoplight switch replacement:Installation . . . . . . . . . . . . . . . . . . . . 3-111b 3-300Removal . . . . . . . . . . . . . . . . . . . . . . . 3-111a 3-300

Stopscrew, accelerator pedal,bracket, rod and,replacement:


Stowage, box cargo,replacement:


Strap, ground, replacement:Ground strap (M939/A1)

installation . . . . . . . . . . . . . . . . . . . 3-129b 3-344Ground strap (M939A2)

installation . . . . . . . . . . . . . . . . . . . 3-129d 3-346Ground strap (M939/A1)

removal . . . . . . . . . . . . . . . . . . . . . . . 3-129a 3-344Ground strap (M939A2)

removal . . . . . . . . . . . . . . . . . . . . . . . 3-129c 3-346Stud, wheel rim, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-222b 3-636Removal............................. 3-222a 3-636

Subframe, dump, replacement:Installation . . . . . . . . . . . . . . . . . . . . . 4-149b 4-746Removal . . . . . . . . . . . . . . . . . . . . . . . 4-149a 4-742

Supply and return tubes(M939/A1), air compressorcoolant, maintenance:

Inspection. . . . . . . . . . . . . . . . . . . . . . 3-55c 3-161Return tube installation . . . . . 3-55e 3-163

Index 59

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Return tube removal . . . . . . . . . . . 3-55b 3-161Supply tube installation . . . . . 3-55d 3-162Supply tube removal . . . . . . . . . . . 3-55a 3-160

Supply lines (M939A2), fueltransfer pump and,maintenance:

Cleaning and inspection...... 3-20b 3-66Installation . . . . . . . . . . . . . . . . . . . . 3-20c 3-67Removal . . . . . . . . . . . . . . . . . . . . . . . 3-20a 3-66

Support bar and bracket, hood,replacement:


Support, center, maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . . 5-50d 5-344Cleaning and inspection...... 5-50c 5-342Disassembly . . . . . . . . . . . . . . . . . . 5-50b 5-342Installation . . . . . . . . . . . . . . . . . . . . 5-50e 5-346Removal . . . . . . . . . . . . . . . . . . . . . . . 5-50a 5-340

Surge tank and bracket(M939A2) replacement:


Surge tank, radiator vent hose,and manifold return hose(M939/A1) replacement:

Radiator vent and manifoldreturn hoses installation... 3-61d 3-182

Radiator vent and manifoldreturn hoses removal . . . . . . . . 3-61a 3-180

Surge tank installation....... 3-61c 3-182Surge tank removal . . . . . . . . . . . . . 3-61b 3-180

Swingfire heater and mountingbracket replacement:


Swingfire heater battery boxheater pad replacement:


Swing-fire heater electricalcomponents replacement:

Circuit breakerinstallation . . . . . . . . . . . . . . . . . . . 3-407f 3-1006

Circuit breaker removal . . . . . . 3-407c 3-1006Electrical connector

installation . . . . . . . . . . . . . . . . . . . 3-407h 3-1008Electrical connector

removal . . . . . . . . . . . . . . . . . . . . . . 3-407a 3-1004Relay installation . . . . . . . . . . . . . 3-407g 3-1008Relay removal . . . . . . . . . . . . . . . . . 3-406b 3-1004Thermal switch

installation . . . . . . . . . . . . . . . . . . . 3-407e 3-1006Thermal switch removal . . . . . 3-407d 3-1006

Index 60

Swingfire heater harnessreplacement:

Para Page


Swingfire heater oil pan shroudand exhaust tubereplacement:


Swingfire heater pumpreplacement:


Swingfire heater water jacketreplacement:


Switch, blackout light,100-volt, receptacle, and,replacement:


Switch, convoy warning light,replacement:


Switch, horn, replacement:Installation . . . . . . . . . . . . . . . . . . . . . 3-104b 3-286Removal . . . . . . . . . . . . . . . . . . . . . . . 3-104a 3-286

Switch, parking brake leverand, replacement:


Switch, pressure, replacement:Installation . . . . . . . . . . . . . . . . . . . . . 3-467b 3-1280Removal . . . . . . . . . . . . . . . . . . . . . . . 3-467a 3-1280

Switch, stoplight, replacement:Installation . . . . . . . . . . . . . . . . . . . 3-111b 3-300Removal . . . . . . . . . . . . . . . . . . . . . . . 3-111a 3-300

Switch, transfer case,replacement:

Installation........................ 4-90b 4-520Removal . . . . . . . . . . . . . . . . . . . . . . 4-90a 4-520

Switches, air conditionermanual starter, replacement:


Switches, electrical,replacement:

Accessory switchesinstallation . . . . . . . . . . . . . . . . . . 3-107b 3-292

Accessory switchesremoval . . . . . . . . . . . . . . . . . . . . . . 3-107a 3-292

TM 9-2320-272-24-4


Tailgate, cargo, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-343b 3-876Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-343a 3-876

Tank and bracket (M939A2),surge, replacement:


Telephone jack post, inside,vreplacement:


INDEX (Contd)

Para Page

Battery and starterswitch installation . . . . . . . . . . . . 3-107d 3-293

Battery and starterswitch removal . . . . . . . . . . . . . . . . . . 3-107c 3-292

T

Telephone jack post, outside,replacement:

Para Page


Telephone post wiring harnessreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-99b 5-602Removal ............................... 5-99a 5-602

Temperature sensor (M939A2),ether atomizer and,replacement:


Tensioner, front winch cable,maintenance:

Assembly ............................ 4-173d 4-829Cleaning and inspection...... 4-173c 4-827Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-173b 4-825Installation ........................ 4-173e 4-830Removal .............................. 4-173a 4-825

Terminal adapter, batterycable and, replacement:


Test equipment setup, powersteering setup:

Installation ........................ 4-122a 4-658Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122b 4-658

Test stand, injector,calibration:

Setting up injector tester..... 5-22a 5-142Test stand calibration ............ 5-22b 5-146

Tests, and adjustment (Ross),power steering:

Poppet adjustment . . . . . . . . . . . . . 4-123d 4-662Steering gear internal

leakage test . . . . . . . . . . . . . . . . . . . . . . 4-123c 4-662Steering pump flow test...... 4-123b 4-661Steering pump pressure

test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123a 4-660Tests, and adjustment

(Sheppard), power steering:Plunger adjustment . . . . . . . . . . . . 4-124d 4-666Steering gear internal

leakage test . . . . . . . . . . . . . . . . . . . . . . 4-124c 4-664Steering pump flow test...... 4-124b 4-664Steering pump pressure

test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124a 4-664Thermal close valve and

bushing, ether, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-36b 3-116Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36a 3-116

Tachometer drive maintenance:Cleaning and inspection...... 4-51b 4-313Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-51c 4-313Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51a 4-313

Tachometer driveshaft(M939/A1) maintenance:

Installation........................... 3-89b 3-256Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89a 3-256

Tachometer pulse sensor(M939/A1) replacement:


Tachometer pulse sensor(M939A2) replacement:

Installation.... . . . . . . . . . . . . . . . . . . . . . . 3-95b 3-270Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95a 3-270

Tachometer, speedometer and,replacement:


Tailgate assembly, dumpreplacement:


Tailgate bumpers replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-261b 3-721Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-261a 3-721

Tailgate control linkage, dump,replacement:


Tailgate personnel stepreplacement:

Index 61

TM 9-2320-272-24-4

Thermostat (M939/A1)maintenance:

Para

INDEX (Contd)

Page

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-65c 3-190Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65a 3-190Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65b 3-190

Thermostat, heater and 10 kWthermostat heater,replacement:

10 kW heater thermostatinstallation . . . . . . . . . . . . . . . . . . . . . . . 4-165d 4-796

10 kW heater thermostatremoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-165b 4-796

Heater thermostatinstallation . . . . . . . . . . . . . . . . . . . . . . . 4-165c 4-796

Heater thermostatremoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-165a 4-796

Thermostats and housing(M939A2) maintenance:

Cleaning and inspection...... 3-66b 3-193Installation (external

bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66e 3-194Installation (internal

bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66c 3-193Removal (external bypass). . 3-66d 3-194Removal (internal bypass) . . 3-66a 3-192

Third clutch maintenance:Cleaning and inspection...... 5-49b 5-338Installation .. . . . . . . . . . . . . . . . . . . . . . . . 5-49c 5-339Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49a 5-338

Throttle control cablemaintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45b 3-136Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-45c 3-136Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45a 3-134

Throttle control solenoid(M939A2) replacement:


Throttle cover and shaftmaintenance:


Throttle kit (M936/A1),automatic, replacement:

Installation ........................ 3-440b 3-1136Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-440a 3-1134

Tie rod maintenance:Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153b 3-424Installation .. . . . . . . . . . . . . . . . . . . . . 3-153c 3-424Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153a 3-424

Tiedown kit, vehicle,replacement:


Index 62

Para Page

Timing pin, front gearcasecover and, maintenance:

Cleaning and inspection...... 4-46c 4-300Front gearcase housing

installation . . . . . . . . . . . . . . . . . . . . . . . 4-46e 4-302Front gearcase housing

removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46a 4-300Timing pin installation....... 4-46d 4-302Timing pin removal . . . . . . . . . . . . . 4-46b 4-300

Timing, engine injector,instructions:

Fuel injectors installation . . . 4-32h 4-242Fuel injectors removal . . . . . . . . . 4-32d 4-238General instructions . . . . . . . . . . . 4-32e 4-238Injector timing . . . . . . . . . . . . . . . . . . . . 4-32g 4-240Rocker lever housing covers

installation . . . . . . . . . . . . . . . . . . . . . . . 4-32k 4-246Rocker lever housing covers

removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32a 4-236Rocker lever housing and

push tubes removal . . . . . . . . . . 4-32b 4-236Rocker lever housing and

push tubes installation..... 4-32j 4-244Timing tool setup . . . . . . . . . . . . . . . . 4-32f 4-240Valve crossheads

installation andadjustment . . . . . . . . . . . . . . . . . . . . . . . 4-32i 4-244

Valve crossheads removal... 4-32c 4-238Tire and tube (M939)

maintenance:Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-220b 3-628Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-220c 3-628Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-220a 3-626

Tire and wheel (M939A1/A2)maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-221b 3-634Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-221a 3-630

Tire, wheel and, rotation(M939):

Front wheel installation . . . . . 3-218f 3-621Inner rear wheel

installation . . . . . . . . . . . . . . . . . . . . . . 3-218d 3-619Wheel and tire removal....... 3-218b 3-616Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-218e 3-620Outer rear wheel

installation . . . . . . . . . . . . . . . . . . . . . . 3-218a 3-616Wheel and tire rotation....... 3-218c 3-618

Tire, wheel and, rotation(M939A1/A2):

Front wheel installation . . . . . 3-219e 3-625Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-219b 3-622Rear wheel installation....... 3-219d 3-624Wheel and tire removal....... 3-219a 3-622Wheel and tire rotation....... 3-219c 3-624

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Toe-in check and adjustment:Toe-in adjustment . . . . . . . . . . . . . . 3-152b 3-422Toe-in check . . . . . . . . . . . . . . . . . . . . . . . . 3-152a 3-422

Toggle clamp anchor postreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-358b 3-897Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-358a 3-897

Toggle clamp, side panel-to-roof, replacement:


Toolbox and stepsreplacement: 3-302b 3-796

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-302a 3-796Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toolbox, spare tire carrier,tractor, replacement:


Top cover gasket and sidecover gasket, carrierdifferential, replacement:

Side cover gasketinstallation . . . . . . . . . . . . . . . . . . . . . . . 3-158d 3-437

Side cover gasket removal... 3-158c 3-437Top cover gasketinstallation ............................. 3-158b 3-436

Top cover gasket removal.... 3-158a 3-434Torque converter,

transmission, maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41d 5-291Cleaning and inspection...... 5-41c 5-290Disassembly . . . . . . . . . . . . . . . . . . . . . 5-41b 5-288Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-41e 5-298Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41a 5-286

Torque rod, upper and lower,maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-170e 3-472Cleaning and inspection...... 3-170c 3-470Diassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-170d 3-470Lower torque rod

installation . . . . . . . . . . . . . . . . . . . . . . . 3-170h 3-474Lower torque rod removal....... 3-170b 3-470Setting preload for upper

torque rod . . . . . . . . . . . . . . . . . . . . . . . . . 3-170f 3-472Upper torque rod

installation . . . . . . . . . . . . . . . . . . . . . . . 3-170g 3-474Upper torque rod removal 3-170a 3-468

Torsion bars andcrossmembers replacement:


Tractor fifth wheelreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-248b 3-696Removal . . . . . . . . . . . . . . . . . . . . . . . 3-248a 3-696

Tractor spare tire carrier(M931, M932) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor spare tire carrier(M931A1/A2, M932A1/A2)replacement:


Tractor spare tire carriertoolbox replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor winch hydraulic oilreservoir (M932/A1/A2)replacement:

Installation ..........................Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer airbrake hand controlvalve (M931/A1/A2,M932/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer coupling hoses(M931/A1/A2, M932/A1/A2),emergency and, replacement:


Transducer (M939/A1), fuelpressure, replacement:


Transducer, pressure,replacement:


Transfer case (M936/A1/A2)replacement:


Transfer case capacitorreplacement:


Transfer case cross shaftreplacement:

3-253b 3-7023-253a 3-702

3-254b 3-7063-254a 3-704

3-250b 3-6993-250a 3-699

3-338b 3-8663-338a 3-864

3-210b 3-5983-210a 3-598

3-209b 3-5963-209a 3-596

3-96b 3-2713-96a 3-271

3-453b 3-12343-453a 3-1232

4-95b 4-5424-95a 4-537

4-91b 4-5224-91a 4-522


Transfer case front axleengagement air cylinderreplacement:

4-87b 4-5144-87a 4-514


Para Page

Index 63

TM 9-2320-272-24-4

INDEX (Contd)

Transfer case front axleengagement control valvereplacement:

Para Page


Transfer case front axle lock-incontrol valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-147b 3-404Removal. . . . . . . . . . . . . . . . . . . . 3-147a 3-404

Transfer case interlock aircylinder replacement:

Installation ......................... 4-83b 4-506Removal . . . . . . . . . . . . . . . . . . . . . . . 4-83a 4-506

Transfer case interlock valve(M936/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-82b 4-504Removal . . . . . . . . . . . . . . . . . . . . . . 4-82a 4-504

Transfer case interlock valvereplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-143b 3-394Removal . . . . . . . . . . . . . . .. . . . . . . 3-143a 3-392

Transfer case oil pumpreplacement:


Transfer case Power Takeoff(PTO) control cablereplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-205b 4-954Removal . . . . . . . . . . . . . .. . . . . . . . . 4-205a 4-954

Transfer case Power Takeoff(PTO) cross shaft (controllever) replacement:


Transfer case Power Takeoff(PTO) maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . 4-208c 4-970Cleaning and inspection...... 4-208b 4-968Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-208a 4-962

Transfer case Power Takeoff(PTO) replacement:


Transfer case repair:Assembly and

adjustment . . . . . . . . . . . . . . . . . . . . . . . 5-63c 5-412Cleaning and inspection...... 5-63b 5-408Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5-63a 5-398

Transfer case replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-94b 4-532Removal . . . . . . . . . . . . . . . . . . . . . . 4-94a 4-528

Para Page

Transfer case shift levermaintenance:

Cleaning, inspection, andrepair.. .............................. 4-85b 4-510


Transfer case shift lever shiftrod maintenance:


Transfer case shift rodmaintenance:

Adjustment.. ....................... 4-88c 4-517Cleaning, inspection, and

repair.. .............................. 4-88b 4-516Installation......................... 4-88d 4-517Removal.............................. 4-88a 4-516

Transfer case speedometerdrive gear and driven shaftreplacement:

Installation......................... 4-89b 4-518Removal.............................. 4-89a 4-518

Transfer case switchreplacement:

Installation......................... 4-90b 4-520Removal.............................. 4-90a 4-520

Transfer case to forward-rearaxle propeller shaftmaintenance:

Assembly............................ 3-150d 3-416Cleaning and inspection ...... 3-150c 3-414Disassembly....................... 3-150b 3-414Installation......................... 3-150e 3-416Removal.............................. 3-150a 3-412

Transfer case transorb diodereplacement:


Transfer case-to-front axlepropeller shaft replacement:


Transfer PTO-to-hydraulicpump propeller shaftreplacement:


Transition, ceiling,maintenance:


Index 64

INDEX (Contd)

Para Page

Transmission 5th gear lock-uppressure switch replacement:


Transmission breatherreplacement:


Transmission control valvereplacement:


Transmission converter stalltest:

Forward stall test . . . . . . . . . . . . . . . 5-62 5-397Transmission converter stall

test:Forward stall test . . . . . . . . . . . . . . . 5-62 5-396

Transmission dipstick tubeand dipstick maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-134c 3-362Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134b 3-362Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134a 3-362

Transmission fifth gear lock-insolenoid replacement:


Transmission governorreplacement:


Transmission housingmaintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59c 5-384Cleaning and inspection...... 5-59b 5-384Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5-59a 5-384

Transmission lubrication valvereplacement:


Transmission manual selectorshaft replacement:


Transmission modulator andcable maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-145c 3-400Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-145b 3-400Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145a 3-398

Transmission modulatormaintenance:

Adjustment............................ 5-6lb 5-394Testing . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 5-61a 5-394

TM 9-2320-272-24-4

Para Page

Transmission mount bushingreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-77b 4-492Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77a 4-492

Transmission mountingbracket and isolator(M939A2) replacement:


Transmission mounting toholding fixture:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-40a 5-284Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40b 5-282

Transmission neutral startswitch replacement:


Transmission oil cooler andmount (M939/A1)replacement:

Oil cooler installation . . . . . . . . . . 3-140d 3-379Oil cooler mount

installation . . . . . . . . . . . . . . . . . . . . . . . 3-140c 3-378Oil cooler mount removal . . . . 3-140b 3-378Oil cooler removal . . . . . . . . . . . . . . . 3-140a 3-378

Transmission oil cooler andmount (M939A2)replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-14lb 3-382Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14la 3-380

Transmission oil cooler filterand head replacement:

Oil cooler filterinstallation . . . . . . . . . . . . . . . . . . . . . . . 3-139d 3-377

Oil cooler filter headinstallation . . . . . . . . . . . . . . . . . . . . . . . 3-139c 3-377

Oil cooler filter headremoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139b 3-376

Oil cooler filter removal....... 3-139a 3-376Transmission oil cooler hoses

replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-142b 3-388Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142a 3-384

Transmission oil pan and filtermaintenance:


Transmission oil pressuretesting:

Automatic shift speed test...... 5-60c 5-392Main pressure andgovernor pressure test....... 5-60b 5-390

Oil cooler pressure test . . . . . . . 5-60a 5-386

Index 65

TM 9-2320-272-24-4

INDEX (Contd)

Para Page Para Page

Transmission oil pump andfront support maintenance:

Assembly ............................ 5-46d 5-316Cleaning and inspection ...... 5-46c 5-314Disassembly.. ..................... 5-46b 5-312Installation.. ....................... 5-46e 5-320Removal.. ............................ 5-46a 5-310

Transmission oil serviceinstructions:

Draining oil.. ....................... 3-133a 3-354Governor filter

installation.. ..................... 3-133e 3-358Governor filter removal....... 3-133d 3-358Oil filter installation.. ......... 3-133c 3-356Oil filter removal.. ............... 3-133b 3-356Replenishing oil .................. 3-133f 3-360

Transmission output shaftyoke and oil seal replacement:


Transmission Power Takeoff(PTO) control cable (M939A2)replacement:


Transmission Power Takeoff(PTO) control cablereplacement:


Transmission Power Takeoff(PTO) maintenance:


Transmission Power Takeoff(PTO) replacement:


Transmission PTO-to-hydraulicpump propeller shaftreplacement:


Transmission PTO-to-hydraulicpump propeller shaftuniversal joint maintenance:Assembly.. .......................... 3-335c 3-856Disassembly.. ..................... 3-335a 3-854Inspection.. ......................... 3-335b 3-854

Transmission replacement (in-vehicle):


Transmission replacement(out-of-vehicle):


Transmission select leverreplacement:


Transmission selector shaft oilseal replacement:


Transmission shift cablemaintenance:


Transmission shift towerreplacement:


Transmission temperaturetransmitter replacement:


Transmission torque convertermaintenance:


Transmission-to-transfer casepropeller shaft maintenance:Assembly.. .......................... 3-148c 3-408Disassembly.. ..................... 3-148b 3-408Installation.. ....................... 3-148d 3-408Removal.. ............................ 3-148a 3-406

Transmitter, transmissiontemperature, replacement:


Troop seat and siderack kit(M929/A1/A2, M930/A1/A2)maintenance:

Siderack assembly.. ............ 3-429c 3-1102Siderack disassembly.. ....... 3-429b 3-1102Troop seat assembly.. ......... 3-429d 3-1102Troop seat disassembly ...... 3-429a 3-1102

Troop seat, cargo, replacement:Installation.. ....................... 3-340b 3-870Removal.. ............................ 3-340a 3-870

Troubleshooting, Central TireInflation System (CTIS) ........ 2-25 2-267

Troubleshooting, compressedair and brake system.. .......... 2-23 2-177

Index 66

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Troubleshooting, direct andgeneral support, mechanical

symptom index . . . . . . . . . . . . . . . . . . . 4-2 4-2Troubleshooting, electrical

system . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 2-92Troubleshooting, mechanical,

unit level . . . . . . . . . . . . . . . . . . . . . . . 2-21 2-61Troubleshooting, STE/ICE

symptom index . . . . . . . . . . . . . . . . . . . 2-24 2-219Tube (M939), tire and,

maintenance:Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-220b 3-628Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-220c 3-628Removal . . . . . . . . . . . . . . . . . . . . . . . 3-220a 3-626

Tube (M939A2) Air FuelControl (AFC), maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-18b 3-61Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-18c 3-61Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-18a 3-61

Tube, air cleaner indicator and,maintenance:

Cleaning and inspection...... 3-12c 3-44Installation . . . . . . . . . . . . . . . . . . . . . 3-12d 3-46Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-12b 3-44Testing . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a 3-42

Tube, cross, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-104b 4-578Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-104a 4-578

Tubes (M939/A1), coolanthoses and, replacement:

Radiator inlet hoses andtube installation . . . . . . . . . . . . . . . 3-54j 3-158

Radiator inlet hoses andtube removal . . . . . . . . . . . . . . . . . . . . . 3-54a 3-154

Radiator outlet hoses andtee installation . . . . . . . . . . . . . . . . 3-54g 3-156

Radiator outlet hoses andtee removal . . . . . . . . . . . . . . . . . . 3-54d 3-156


radiator bypass tube, andhose installation . . . . . . . . . . . . . . . 3-54i 3-158

Thermostat housing hose,radiator bypass tube, andhose removal.. . . . . . . . . . . . . . . . . 3-54b 3-154


Transmission oil coolerhoses and tube removal . . . . 3-54e 3-156

Tubes (M939A2), aftercoolerand, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . 3-76b 3-218Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76a 3-216

Para Page

Tubes (M939A2), aftercoolerand, replacement:


Tubing, ether, replacement:Installation.. ....................... 3-39b 3-120Removal .............................. 3-39a 3-120

Turbocharger and coolant lines(M939A2) replacement:


Turbocharger maintenance:Assembly.. .......................... 4-58c 4-348Cleaning and inspection ...... 4-58b 4-348Disassembly.. ..................... 4-58a 4-346

Turn signal control andindicator lamp replacement:


Turn signal flasherreplacement:


Turnbuttons and lashinghooks, cab, replacement:


Turntable repair:Assembly.. .......................... 4-203d 4-948Cleaning, inspection,


Underframe parts replacement:Installation.. ....................... 5-71b 5-484Removal.. ............................ 5-71a 5-484

U

Unit Preventive MaintenenceChecks and Services (PMCS):

General.. ............................. 2-8 2-2Intervals.. ........................... 2-9 2-2Reporting repairs ................ 2-10 2-3General service and

inspection procedures ........ 2-11 2-3Specific PMCS procedures ... 2-12 2-3

Universal joint, front axle shaftand, maintenance:

Cleaning and inspection ...... 3-154b 3-426Installation.. ....................... 3-154e 3-429Removal.. ............................ 3-154a 3-426Universal joint assembly.... 3-154d 3-428Universal joint disassembly 3-154c 3-428

Index 67

TM 9-2320-272-24-4

INDEX (Contd)

Universal joint, PTO-to-hydraulic pump propellershaft, transmission,maintenance:

Para Page


Upper and lower steeringcolumn maintenance:

Cleaning, inspection,and repair . . . . . . . . . . . . . . . . . . . . . . . . . 4-116c 4-608

Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-116b 4-608Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-116e 4-612Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-116d 4-610Removal . . . . . . . . . . . . . . .. . . . . . . . 4-116a 4-606

Upper and lower torque rodmaintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-170e 3-472Cleaning and inspection...... 3-170c 3-470Diassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-170d 3-470Lower torque rod

installation . . . . . . . . . . . . . . . . . . . . . . . 3-170h 3-474Lower torque rod removal... 3-170b 3-470Setting preload for upper

torque rod . . . . . . . . . . . . . . . . . . . . . 3-170f 3-472Upper torque rod

installation . . . . . . . . . . . . . . . . . . . . . . . 3-170g 3-474Upper torque rod removal... 3-170a 3-468

Upper bracket, rear axlesspring seat wear pads and,maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168b 3-462Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-168c 3-462Removal . . . . . . . . . . . . . . . . .. . . . . . 3-168a 3-460

Upper radiator hoses andbrackets (M939A2)replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-58b 3-170Removal . . . . . . . . . . . . . . . . . . . . . 3-58a 3-170

Use of metric system . . . . . . . . . . . . . . . 1-9 1-3

V

Valve (M936/A1/A2), brakepedal (treadle), replacement:


Valve (M936/A1/A2), transfercase interlock, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-82b 4-504Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-82a 4-504

Valve adjustment:Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-53a 4-326

Para Page

Valve and injector adjustment(dial indicator method):

Checking plunger freetravel . . . . . . . . . . . . . . . . . . . . . . . . . 4-33a 4-248

Injector and valveadjustments . . . . . . . . . . . . . . . . . . . . . 4-33b 4-248

Valve cover (M939A2)maintenance:

Cleaning and inspection...... 3-6b 3-26Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c 3-26Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-6a 3-22

Valve No. 1, doublecheck,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-212b 3-602Removal . . . . . . . . . . . . . . . . . . . . . 3-212a 3-602

Valve No. 2 (M931/A1/A2,M932/A1/A2), doublecheck,replacement:


Valve No. 2 (M931/A1/A2,M932/A1/A2), doublecheck,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-214b 3-606Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-214a 3-606

Valve No. 2, doublecheck,(M93/A1/A2, M9321/A1/A2)replacement:


Valve No. 2, doublecheck,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-213b 3-604Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-213a 3-604

Valve No. 5, doublecheck,(M931/A1/A2,M932/A1/A2)replacement:


Valve seat insertsmaintenance:

Cleaning . . . . . . . . . . . . . . . . . . . . . . 5-5d 5-24Counterboring . . . . . . . . . . . . . . . . . . . . . 5-5c 5-24Gauging . . . . . . . . . . . . . . . . . . . . . . 5-5b 5-22Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-5e 5-24Removal . . . . . . . .. . . . . . . . . . . . . . 5-5a 5-22

Valve switch, fuel selector,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-109b 3-296Removal . . . . . . . . .. . . . . . . . . . . . . . 3-109a 3-296

Valve, air supply, handairbrake, replacement:

Installation ........................ 3-422b 3-1084Removal . . . . . . . . .. . . . . . . . . . . . . 3-422a 3-1084

Index 68

Valve, assembly, snubber,replacement:


Valve, brake pedal (treadle)repair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning and inspection......Disassembly . . . . . . . . . . . . . . . . . . . . . . .

Valve, brake pedal (treadle),replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve, Check, air reservoir one-way, replacement:


Valve, crane control, repair:Assembly . . . . . . . . . . . . . . . . . . . . . .Cleaning, inspection,

and repair . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . .

Valve, crane swivel,maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring harness

connection.. . . . . . . . . . . . . . . . . . . . . . . .Wiring harness

disconnection . . . . . . . . . . . . . . . . . .Valve, deepwater fording

pressurization, replacement:Installation (M939/A1) . . . . . . .Installation (M939A2) . . . . . . . .Removal (M939/A1) . . . . . . . . . . .Removal (M939A2) . . . . . . . . . . . . .

Valve, deepwater fordingregulator, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . .

Valve, doublecheck,handairbrake, replacement:

Installation (forward-rearaxle doublecheck valve). . . . .

Installation (rear-rearaxle doublecheck valve). . . .

Removal (forward-rearaxle doublecheck valve). . . . .

Removal (rear-rear axledoublecheck valve) . . . . . . . . . . . .

Valve, ether cylinder and,replacement:

Ether cylinder installation . .Ether cylinder removal . . . . . . . .Ether valve installation . . . . . .Ether valve removal . . . . . . . . . . . .

Para Page

TM 9-2320-272-24-4

INDEX (Contd)

3-390b 3-9583-390a 3-958

4-108c 4-5864-108b 4-5864-108a 4-584

3-197b 3-5383-197a 3-536

3-186b 3-5143-186a 3-514

5-108c 5-640

5-108b 5-6405-108a 5-636

4-198c 4-9304-198b 4-928

4-198d 4-932

4-198a 4-926

4-226b 4-10324-226c 4-10304-226a 4-10284-226b 4-1030

4-228b 4-10404-228a 4-1040

3-424b 3-1088

3-424d 3-1090

3-424a 3-1088

3-424c 3-1090

3-35d 3-1153-35a 3-1143-35c 3-1153-35b 3-114

Para Page

Valve, front wheel,maintenance:


Valve, hand airbrakecontroller, replacement:


Valve, hand air-brake tractorprotection, valve replacement:


Valve, injector plunger (torquemethod) and, adjustments:

Injector and valveadjustment.. ..................... 4-34b 4-256

Pre-adjustment setup.. ....... 4-34a 4-254Valve, interlock, transfer case,


Valve, modulator lockup, lowtrimmer valve, and low shiftvalve, replacement:


Valve, pneumatic controllerand relief, maintenance:


Valve, pressure relief,maintenance:


Valve, rear wheel,maintenance:Cleaning and inspection ...... 3-457b 3-1246Installation.. ....................... 3-457c 3-1247Removal.. ............................ 3-457a 3-1246

Valve, relay, repair:Assembly.. .......................... 4-109c 4-590Cleaning and inspection ...... 4-109b 4-590Disassembly.. ..................... 4-109a 4-590

Valve, relief safety,maintenance:

Assembly.. .......................... 3-455d 3-1242Cleaning and inspection ...... 3-455c 3-1242Disassembly.. ..................... 3-455b 3-1241Installation.. ....................... 3-455e 3-1242Removal .............................. 3-455a 3-1240

Index 69

TM 9-2320-272-24-4

Valve, spring brake,maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . .

Valve, transmissionlubrication, replacement:

Installation. . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . .

Valve, wheel, maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . .Cleaning and inspection. . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . .

Valves No. 3, No. 4,doublecheck and quick-release valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . .

Valves, intake and exhaust,refacing:

Cleaning after refacing.. . . . . . .Grinding or refacing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve specifications . . . . . . . . . . . . .

Van air conditioner wiringharness replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . .

Van body replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van davit chain and wire ropereplacement:


Van davit chain and wire ropereplacement:

Installation. . . . . . . . . . . . . . . . . . . . . . .Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van davit winch (M934A1/A2)replacement:


Van handrail modification kit(M9341/A1/A2) replacement:

Door check spacerinstallation . . . . . . . . . . . . . . . . . . . . . . .

Door check spacerremoval. . . . . . . . . . . . . . . . .. . . .

Ladder handrail guideinstallation . . . . . . . . . . . . . . . . .

Ladder handrail guideremoval . . . . . . . . . . . . . . . . . . . . .

Index 70

Para Page Para Page

INDEX (Contd)

3-173b 3-4823-173c 3-4823-173a 3-482

4-79b 4-4984-79a 4-496

3-459c 3-12503-459b 3-12503-459a 3-1250

3-216b 3-6123-216a 3-610

5-4c 5-20

5-4b 5-205-4a 5-18

5-90b 5-5705-90a 5-570

5-66b 5-4665-66a 5-464

3-264b 3-7243-264a 3-724

3-264b 3-7243-264a 3-724

3-266b 3-7283-266a 3-728

3-450h 3-1229

3-450g 3-1229

3-450b 3-1225

3-450a 3-1225

Ladder handrail hangersinstallation . . . . . . . . . . . . . . . . . . . 3-450d 3-1226

Ladder handrail hangersremoval . . . . . . . . . . . . . . . . . . . . . . 3-450c 3-1226

Van door grab handlesinstallation . . . . . . . . . . . . . . . . . . 3-450f 3-1228

Van door grab handlesremoval . . . . . . . . . . . . . . . . . . . . . 3-450e 3-1228

Van heater and exhaustreplacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-379b 3-930Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-379a 3-928

Van heater fuel pump(M934A1/A2) replacement:

Installation (M934) . . . . . . . . . . . . . 3-381d 3-936Installation (M934A1/A2)... 3-381b 3-934Removal (M934) . . . . . . . . . . . . . . . . . . 3-381c 3-936Removal (M934A1/A2)........ 3-381a 3-934

Van heater wiring harnessreplacement:

Installation . . . . . . . . . . . . . . . . . . . . 5-91b 5-574Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5-91a 5-572

Van power cable reel(M934A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-380b 3-932Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-380a 3-932

Van rear door and side doorwindow replacement:

Installation ........................ 3-350b 3-888Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-350a 3-888

Van spare tire carrier (M934)replacement . . . . . . . . . . . . . . . . . . . . . 3-262 3-722

Van spare tire carrier(M934A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-263b 3-722Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-263a 3-722

Van swing davit and pulleyreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-265b 3-726Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-265a 3-726

Vavle, crane control,replacement:


Vehicle tiedown kitreplacement:


Vent door weathersealreplacement:


Vent, screen and door, cabcowl, replacement:


INDEX

Para Page

Vibration dampermaintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42b 4-290Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-42c 4-290Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-42a 4-290

Voltage regulator, 100-amp,replacement:


VS governor filter, fuel pumpwith, replacement:


W

Warning light, amber,replacement:


Warning light, convoy,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-437b 3-1128Removal . . . . . . . . . . . . . . . . . . . .. . . . 3-437a 3-1128

Warning module, failsafe,replacement:


Warranty information . . . . . . . . . . . . . 1-7 1-2Washer control valve

replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-191b 3-524Removal . . . . . . . . . . . . . . . . . . . .. . . . . 3-191a 3-524

Washer hoses, windshield,replacement:


Water header platesreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-28b 4-198Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28a 4-198

Water jacket, swingfire heater,replacement:

Installation ....................... 3-411b 3-1020Removal . . . . . . . . . . . . . . . . . . . . . . . 3-411a 3-1020

Water pump (M939/A1)maintenance:

Assembly . . . . . . . . . . . . .. . . . . . . . . . 4-63c 4-384Cleaning and inspection...... 4-63b 4-381Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-63a 4-378

Water pump (M939/A1)replacement:


TM 9-2320-272-24-4

(Contd)

Para Page

Water pump (M939A2)maintenance:


Water pump drivebelt(M939/A1) maintenance:


Water pump maintenance:Assembly.. .......................... 4-29d 4-206Cleaning and inspection ...... 4-29c 4-204Disassembly.. ..................... 4-29b 4-202Installation.. ....................... 4-29e 4-208Removal.. ............................ 4-29a 4-200

Water separator maintenance:Assembly.. .......................... 3-466d 3-1278Cleaning and inspection...... 3-466c 3-1278Disassembly.. ..................... 3-466b 3-1278Installation.. ....................... 3-466e 3-1279Removal.. ............................ 3-466a 3-1278

Water temperature sendingunit replacement:


Weapon station modificationkit, lightweight, maintenance:


Weatherseal, cab door,replacement:


Weatherseal, vent door,replacement:


Weatherstripping (cab door),window, replacement:


Weight, governor, maintenance:Inspection.. ......................... 5-17b 5-102Installation.. ....................... 5-17c 5-102Removal .............................. 5-17a 5-102

Wet air reservoir (supply tank)and bracket replacement:


Index 71

TM 9-2320-272-24-4

INDEX

Para Page

Wet air reservoir (supply tank)and mounting plate(M936/A1/A2) replacement:


Wet reservoir (supply tank)safety valve replacement:


Wheel (M939A1/A2), tire and,maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-221b 3-634Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-221a 3-630

Wheel and tire rotation(M939):

Front wheel installation . . . . . 3-218f 3-621Inner rear wheel

installation . . . . . . . . . . . . . . . . . 3-218d 3-619Wheel and tire removal....... 3-218a 3-616Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-218b 3-616Outer rear wheel

installation . . . . . . . . . . . . . . . . . . . . . . . 3-218e 3-620Wheel and tire rotation....... 3-218c 3-618

Wheel and tire rotation(M939A1/A2):

Front wheel installation . . . . . 3-219e 3-625Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-219b 3-622Rear wheel installation....... 3-219d 3-624Wheel and tire removal....... 3-219a 3-622Wheel and tire rotation....... 3-219c 3-624

Wheel bearing adjustment:Front wheel bearingadjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-225a 3-648Rear wheel bearingadjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-225b 3-650

Wheel brakedrum dustcoversreplacement:

Front wheel dustcoversinstallation . . . . . . . . . . . . . . . . . . . . . . . 3-178c 3-496

Front wheel dustcoversremoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-178a 3-496

Rear wheel dustcoversinstallation . . . . . . . . . . . . . . . . . . . . . . . 3-178d 3-496

Rear wheel dustcoversremoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-178b 3-496

Wheel rim stud replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-222b 3-636Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-222a 3-636

Wheel valve filter replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-458b 3-1248Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-458a 3-1248

Wheel valve maintenance:Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-459c 3-1250Cleaning and inspection...... 3-459b 3-1250Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-459a 3-1250

Index 72

(Contd)

Para Page

Wheel, steering, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-226b 3-652Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-226a 3-651

Winch automatic brake, front,adjustment:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-323b 3-826Testing ............................ 3-323a 3-824

Winch cable chain and hook,front, replacement:


Winch cable clevis replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-326b 3-832Removal . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 3-326a 3-831

Winch cable tensioner, rear,repair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-182c 4-882Cleaning, inspection,

and repair . . . . . . . . . . . . . . . . . . . . . . . . . 4-182b 4-880Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-182a 4-878

Winch cable, front,replacement:


Winch cable, rear, replacement:Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 lb 3-846Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 la 3-846

Winch control valve(M930/A1/A2), front,replacement:


Winch control valve cable,front, replacement:


Winch control valve, front andrear, replacement:


Winch drag brake, front,adjustment:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-324b 3-828Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-324a 3-828

Winch frame extensionreplacement:


Winch hydraulic hose and tube,front, replacement:


Winch hydraulic motor, rear,replacement:


INDEX

Para Page

Winch hydraulic oil reservoirreplacement:


Winch level wind, front andrear, maintenance:

Assembly ............................ 4-174d 4-839Cleaning, inspection,


Winch motor and lines,hydraulic hoist, replacement:


Winch motor, front,replacement:


Winch roller, rear, repair:Cleaning and inspection...... 4-153c 5-754Side roller assembly ............ 4-153e 4-754Side roller disassembly ....... 4-153a 4-752Top and bottom roller

assembly.. ........................ 4-153d 4-754Top and bottom roller

disassembly.. .................... 4-153b 4-752Winch side roller, repair:


Winch top and bottom roller,rear, repair:

Assembly ............................ 4-184c 4-887Cleaning and inspection...... 4-184b 4-886Disassembly.. ..................... 4-184a 4-886

Winch, front, repair:Assembly ofsubassemblies.. .................. 4-172d 4-819Assembly of winch.. ............ 4-172e 4-823Cleaning, inspection,

and repair.. ....................... 4-172c 4-816Disassembly into

subassemblies.. ................ 4-172a 4-810Disassembly of

subassemblies.. ................ 4-172b 4-812Winch, front, replacement:


Winch, hoist replacement:Installation.. ....................... 4-192b 4-908Removal .............................. 4-192a 4-908

Winch, hoist, PTOmaintenance.. ....................... 5-101 5-606

TM 9-2320-272-24-4

(Contd)

Para Page

Winch, hydraulic pump, front,replacement:


Winch, rear, adjustment:Cable tensioner

adjustment.. ..................... 3-330b 3-844Cable tensioner

check.. ............................... 3-330a 3-844Winch, rear, repair:


Winch, rear, replacement:Installation.. ....................... 3-332b 3-848Removal.. ............................ 3-332a 3-847

Winch, roller assembly, front,maintenance:



Window blackout panelreplacement:


Window brushguardreplacement:


Window glass, retractable andvan door, replacement:


Window regulator and insidedoor handle replacement:


Window regulator, retractable,replacement:


Window screen replacement:Installation.. ....................... 3-353b 3-891Removal.. ............................ 3-353a 3-891

Window weatherstripping (cabdoor) replacement:


Window, retractable,replacement:


Index 73

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Window, van rear door andside door, replacement:


Windshield and outer frameassembly replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-278b 3-752Removal . . . . . . . . . . . . . . . . . . . . . .. . 3-278a 3-752

Windshield frame assemblyreplacement:


Windshield hinge, cabassembly, replacement:


Windshield stop bracket andlatch replacement:


Windshield washer hosesreplacement:


Windshield wiper control valvereplacement:


Windshield wiper reservoir, jet,and control replacement:


Windshield, cab, repair:Assembly . . . . . . . . . . . . . . . . . . . . 4-138b 4-708Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-138a 4-708

Wiper motor, windshield wiperblade, wiper arm, and,replacement:


Wire, boom, floodlight,replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-385b 3-946Removal . . . . . . . . . . . . . . . . .. . . . . . . 3-385a 3-946

Wiring harness (M939/A2),front, replacement:


Wiring harness (M939A2),front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-67b 4-434Removal . . . . . . . . . . . . . . . . . .. . . . . . 4-67a 4-422

Para Page

Wiring harness repair:Female cable connector(with sleeve). ..................... 3-131c 3-350

Male cable connector.. ......... 3-131b 3-350Plug assembly.. .................. 3-131d 3-350Receptacle assembly.. ......... 3-131e 3-350Terminal-type cable

connector.. ......................... 3-131a 3-349Wiring harness, 3-phase

receptacle, replacement:Installation.. ....................... 5-100b 5-604Removal.. ............................ 5-100a 5-604

Wiring harness, 400 Hz supply,replacement:


Wiring harness, air conditioner,van, replacement:


Wiring harness, blackout andclearance lights, replacement:


Wiring harness, blackoutbypass, maintenance:


Wiring harness, brached 400Hz receptacle, replacement:


Wiring harness, crane,replacement:


Wiring harness, CTIS,replacement:


Wiring harness, electric heater(10 kw), replacement:


Wiring harness, emergencylamp, replacement:


Index 74

TM 9-2320-272-24-4

INDEX (Contd)

Para Page

Wiring harness, flexibleconverter, maintenance:

Installation.. .......................Removal..............................Repair.. ...............................

Wiring harness, heater fuelpump, maintenance:

Installation.. .......................Removal..............................Repair.. ...............................

Wiring harness, main,replacement:


Wiring harness, rear,replacement:


Wiring harness, telephonepost, replacement:


Wiring harness, van heater,replacement:


Wrecker body replacement:Installation .........................Removal.. ............................

Wrecker crane hydraulic hoseand tube replacement:


Wrecker crane hydraulic pumpreplacement:


4-160c 4-7744-160a 4-7744-160b 4-774

4-156c 4-7664-156a 4-7664-156b 4-766

5-89b 5-5685-89a 5-568

4-68b 4-4544-68a 4-446

5-99b 5-6025-99a 5-602

5-91b 5-5745-91a 5-572

4-152b 4-7504-152a 4-748

3-387b 3-9523-387a 3-952

3-388b 3-9543-388a 3-954

Index 75/(Index 76 blank)

By Order of the Secretary of the Army:

DENNIS J. REIMERGeneral, United States Army

Chief of Staff

Administrative Assistant to theSecretary of the Army

04876

DISTRIBUTION: T o b e d i s t r i b u t e d i n a c c o r d a n c e w i t h t h e i n i t i a l d i s t r i b u t i o nnumber (IDN) 381074 requirements for TM 9-2320-272-24-4.

*U.S. GOVERNMENT PRNITING OFFICE:1998-646-.039/80045

THE METRIC SYSTEM AND EQUIVALENTSLINEAR MEASURE1 Centimeter = 10 Millimeters = 0.01 Meters =

0.3937 Inches1 Meter = 100 Centimeters = 1,000 Millimeters =

39.37 Inches1 Kilometer = 1,000 Meters = 0.621 Miles

SQUARE MEASURE

LIQUID MEASURE1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces1 Liter = 1,000 Milliliters = 33.82 Fluid Ounces

TEMPERATURE5/9 (oF -32) - oC212o Fahrenheit is equivalent to 100o Celsius90o Fahrenheit is equivalent to 32.2o Celsius32o Fahrenheit is equivalent to 0o Celsius9/5 oC +32 = oF

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles

CUBIC MEASURE1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet

WEIGHTS1 Gram = 0.001 Kilograms = 1,000 Milligrams = 0.035 Ounces1 Kilogram = 1,000 Grams = 2.2 Lb1 Metric Ton = 1,000 Kilograms = 1 Megagram = 1.1 Short Tons

APPROXIMATE CONVERSION FACTORSTO CHANGE TO MULTIPLY BYInches . . . . . . . . . . . . . . . . . . . . . . . . . Cent imeters . . . . . . . . . . . . . . . . . 2.540Feet . . . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . 0.305Yards . . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . 0.914Miles . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . 1.609Square Inches . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . . 6.451Square Feet . . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . 0.093Square Yards . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . 0.836Square Miles . . . . . . . . . . . . . . . . . . . Square Kilometers . . . . . . . . . . . . 2.590Acres . . . . . . . . . . . . . . . . . . . . . . . . . . Square Hectometers . . . . . . . . . . 0.405Cubic Feet . . . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . 0.028Cubic Yards . . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . 0.765Fluid Ounces . . . . . . . . . . . . . . . . . . . Milliliters . . . . . . . . . . . . . . . . . . . 29.573P i n t s . . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . 0.473Quarts . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . 0.946Gallons. . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . 3.735Ounces . . . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . . 28.349Pounds . . . . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . . . . . . 0.454Short Tons . . . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . 0.907Pound-Feet . . . . . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . 1.356Pounds Per Square Inch . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . . 6.895Miles Per Gallon . . . . . . . . . . . . . . . . Kilometers Per Liter . . . . . . . . . . 0.425Miles Per Hour . . . . . . . . . . . . . . . . . Kilometers Per Hour . . . . . . . . . . 1.609

TO CHANGE TO MULTIPLY BYCentimeters . . . . . . . . . . . . . . . . . . . . Inches . . . . . . . . . . . . . . . . . . . . . . 0.394Meters . . . . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . . 3.280Meters . . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . 1.094Kilometers . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . . 0.621Square Centimeters . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . 0.155Square Meters . . . . . . . . . . . . . . . . . . Square Feet . . . . . . . . . . . . . . . . . 10.764Square Meters . . . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . 1.196Square Kilometers . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . 0.386Square Hectometers . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . . 2.471Cubic Meters . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . 35.315Cubic Meters . . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . 1.308Milliliters . . . . . . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . 0.034Liters . . . . . . . . . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . . 2.113Liters . . . . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . 1.057Liters . . . . . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . . 0.264Grams. . . . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . . 0.035Kilograms. . . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . . . . . 2.205Metric Tons . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . 1.102Newton-Meters . . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . . 0.738Kilopascals . . . . . . . . . . . . . . . . . . . . . Pounds Per Square Inch . . . . . . . 0.145Kilometers Per Liter . . . . . . . . . . . . . Miles Per Gallon . . . . . . . . . . . . . 2.354Kilometers Per Hour . . . . . . . . . . . . . Miles Per Hour . . . . . . . . . . . . . . 0.621

PIN: 076652-000

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